The 38-page document, released Wednesday, paints the manufacturer’s quality control practices as inadequate and its workforce as insufficiently trained, blaming it for cost increases and schedule delays in the development of NASA’s Space Launch System (SLS) Block 1B. Yet the space agency has neglected to punish Boeing financially for these flaws, arguing that doing so would run contrary to the terms of its contract.

The heavy-lift rocket, a more powerful configuration of NASA’s existing SLS Block 1, is intended to make its maiden voyage in 2028 on the Artemis IV mission, a crewed lunar landing. It has been under development since 2014. Boeing is under contract to build Block 1B’s Exploration Upper Stage (EUS)—which will increase the SLS’ cargo capacity by about 40 percent—as well as the core stages for Block 1 on Artemis I and the upcoming Artemis II. Other SLS contractors include Aerojet Rocketdyne and Northrop Grumman.

A Day Late, A Dollar Short

Originally, the EUS was allocated a budget of $962 million and intended to fly on Artemis II, which in January was pushed to no earlier than September 2025. But by the OIG’s estimate, EUS costs are expected to balloon to $2 billion through 2025 and reach $2.8 billion by the time Artemis IV lifts off in 2028.

The office projects total SLS Block 1B costs will hit $5.7 billion before then—that’s more than $700 million over the Agency Baseline Commitment (ABC) NASA made last year. The EUS, at nearly triple its original budget, would account for close to half of those costs.

Add to that an expected six-year delay in the delivery of the system, and the OIG predicts Artemis IV’s launch could be postponed.

“NASA’s fiscal year 2024 SLS Program budget projections do not account for the additional funds needed for EUS development in fiscal years 2024 through 2027,” the report says. “Without additional funding, scheduled work will continue to be pushed into subsequent years as has been the case for the EUS over the last decade, leading to further cost increases and schedule delays.”

For example, the OIG says, NASA is evaluating potential risks to the EUS stage controller and avionics that could delay its delivery by another 14 months. NASA officials disagreed with the analysis.

Mismanaged and Inexperienced

The OIG interviewed officials at NASA headquarters, Marshall Space Flight Center, Michoud Assembly Facility, the Defense Contract Management Agency (DCMA), and Boeing. It also reviewed NASA and its contractors’ budgets, contract obligations, and quality control documents, among other materials.

In short, the office found that Boeing’s quality management system at Michoud does not adhere to NASA or international standards.

For example, Boeing Defense’s Earned Value Management System (EVMS)—which NASA uses to measure contract cost and schedule progress and is required on all projects with a lifecycle cost greater than $250M—has been disapproved by the Department of Defense since 2020. Officials claim this precludes Boeing from reliably predicting an EUS delivery date.

“Boeing’s process for addressing contractual noncompliance has been ineffective, and the company has generally been nonresponsive in taking corrective actions when the same quality control issues reoccur,” the OIG says.

The DCMA has issued several corrective action requests (CARs), handed down when quality control issues are identified, for the EVMS. Between September 2021 and September 2023, the agency issued Boeing a whopping 71 CARs after identifying quality control issues in the manufacturing of core and upper stages at Michoud. According to officials, that’s a massive number for a system that has been in development for so long.

“Boeing officials incorrectly approved hardware processing under unacceptable environmental conditions, accepted and presented damaged seals to NASA for inspection, and used outdated versions of work orders,” the report says. “DCMA also found that Boeing personnel made numerous administrative errors through changes to certified work order data without proper documentation.”

According to Safety and Mission Assurance officials at NASA and DCMA officials at Michoud, Boeing’s quality control issues stem from a workforce that is, by and large, unqualified.

During a visit to Michoud in 2023, for example, inspectors discovered that welding on a component of the SLS Core Stage 3 did not meet NASA standards. Per the report, unsatisfactory welding performed on a set of fuel tanks led directly to a seven-month delay in EUS completion.

“According to NASA officials, the welding issues arose due to Boeing’s inexperienced technicians and inadequate work order planning and supervision,” the OIG says. “The lack of a trained and qualified workforce increases the risk that Boeing will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards.”

Complicating matters further is the relocation of SLS core stage production for Artemis III from Michoud to Kennedy, which will require Boeing to transition a decade of production processes developed at the former site to the latter.

The OIG said the manufacturer is developing a more robust, hands-on training program that could revamp its workforce but is long overdue.

“Some technicians reported they had to hunt through layers of documentation to identify required instructions and documentation of work history and key decisions related to the hardware,” the report says.

Further, maintaining that workforce may be difficult—the OIG predicts Boeing will spend an average of $26 million per month on EUS personnel through 2027. That was the norm for the company from February to August 2023.

Boeing management has also dropped the ball at higher levels. For instance, in the leadup to Artemis I, Boeing underestimated the complexity of building the SLS core stage, and EUS funding had to be redirected to that project.

“This ultimately led to a nearly one-year delay in EUS work and an additional $4 billion in funding to Boeing to cover the costs for the core stage development work,” according to the OIG.

In addition, NASA officials believe Boeing’s supply chain woes are of its own making, stemming from late negotiations and contract agreements.

Next Steps for NASA

The OIG report paints the picture of a company in disarray from top to bottom.

The office did not pin the blame entirely on Boeing. It criticized NASA, for example, for spending more than $3 billion over ten years without submitting an ABC to Congress and the Office of Budget and Management. The ABC is the only official cost and schedule baseline used to measure project performance against expectations.

The office’s four recommendations, however, center around the manufacturer.

First, the OIG calls on the associate administrator of NASA’s Exploration Systems Development Mission Directorate (ESDMD), alongside the agency’s assistant administrator for procurement and chief of safety and mission assurance, to collaborate with Boeing on a more robust, NASA-approved quality management system. It also recommends officials penalize the company financially for its previous violations.

The OIG further directs the ESDMD to conduct a cost overrun analysis of Boeing’s EUS contract to minimize the impact to Artemis missions. Finally, it asks the associate administrator to coordinate with the DCMA to ensure Boeing’s compliance with EVMS requirements.

NASA agreed with three of the four recommendations and proposed actions to take. Interestingly, though, it rejected the suggestion of fining Boeing.

“NASA interprets this recommendation to be directing NASA to institute penalties outside the bounds of the contract,” said Catherine Koerner, deputy associate administrator of the ESDMD, in NASA’s response to the report. “There are already authorities in the contract, such as award fee provisions, which enable financial ramifications for noncompliance with quality control standards.”

Essentially, the agency believes it can keep Boeing in check by rewarding good behavior rather than penalizing mismanagement. The OIG, predictably, disagrees, characterizing NASA as “unresponsive” to what it considers significant safety concerns.

“In the end, failure to address these issues may not only hinder the Block 1B’s readiness for Artemis IV but also have a cascading impact on the overall sustainability of the Artemis campaign and NASA’s deep space human exploration efforts,” the report says.

Boeing will look to improve some of its quality control issues under the leadership of new CEO Kelly Ortberg, the ex-boss of Rockwell Collins who took over after the ousting of former CEO Dave Calhoun.

Calhoun’s departure this month comes as the company continues to be grilled over the loss of a door plug on a Boeing 737 Max 9 in January as well as persistent issues with Starliner, its semireusable spacecraft under contract with NASA for astronaut rotation missions to the  International Space Station. Astronauts Butch Wilmore and Suni Williams may end up spending eight months on the orbital laboratory, rather than eight days as intended.

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On Wednesday in Washington, D.C., NTSB Chair Jennifer Homendy noted the investigation into the door plug blowout in January near Portland, Oregon, has revealed that the message to Boeing workers is “you mess up, you get moved.”

The 737 flying as Alaska Airlines Flight 1282 had been in service less than four months when it lost a door plug on January 5 shortly after takeoff from Portland International Airport (KPDX). The airline grounded its fleet of 737 Max 9s and the FAA followed suit, keeping the airplanes on the ground out of an abundance of caution.

• READ MORE: NTSB Grills Boeing Over Max 9 Door Plug Loss

Within two weeks, the NTSB determined the door plug had been reinstalled without four retaining bolts. Two crews who flew the aircraft prior to the blowout reported issues with the pressurization system. The aircraft was slated to go into maintenance.

On the first day of testimony on Tuesday, Boeing officials stated that during the build process the door plug was removed from the fuselage at the Renton, Washington, factory in order to replace substandard rivets. The required paperwork authorizing and tracking the removal and subsequent reinstallation has still not been found.

Homendy stressed that no evidence has been discovered to suggest the improper installation of the door plug was anything more than a mistake. Boeing has stated there is a no-retaliation policy, and it should not implement disciplinary action for unintentional mistakes.

However, Homendy questioned that assertion, citing a decision by Boeing to move two members of the door installation crew from the plant at Renton to the factory in Everett, Washington, describing it as “a form of retaliation.” There were references to Boeing employees calling the Everett facility a “cage,” “jail,” or “prison” for workers who speak up about safety issues or report mistakes.

• READ MORE: Boeing Names New CEO to Lead Through ‘Consequential Period’

During the proceedings there were several mentions of how lucky the people aboard Alaska Airlines Flight 1282 had been, as there were injuries but no loss of life. Several officials noted that had the aircraft been much higher, the damage and outcome likely would have been much different.

A representative from the flight attendants union described his emotions when he learned of the blowout on the jet that had only been in service since October, realizing he had been assigned to the aircraft on a previous trip.

Much of the testimony over the past two days carried the theme of an “accident waiting to happen” because of a lack of oversight, rush jobs, and hastily trained and overworked technicians. Those who testified spoke of a factory culture where employee training is rushed or sometimes incomplete. In addition, employee turnover is frequent, resulting in employees with limited experience who don’t recognize a mistake or hazard on the floor during the build process.

Boeing officials touted the “speak up” process that encourages employees to call attention to airplane safety issues by reporting them to a manager or anonymously. However, many employees when questioned stated that they were not familiar with the “speak up” process, or they feared retaliation, saying “nothing within the Boeing system is confidential.”

• READ MORE: Boeing to Plead Guilty in DOJ 737 Max Crash Cases

It was noted that Boeing has faced accusations of retaliation against whistleblowers in the past, most notably in 2018 and 2019 after the two 737 Max crashes that killed 346 people. Both crashes were attributed to the MCAS, an automated system that put the aircraft into unrecoverable dives shortly after takeoff. The subsequent investigation revealed the pilots had not been told of or trained on the use of the system.

FAA representatives stated that the agency hotline has received an increase in reports of safety concerns from Boeing employees and those from Spirit AeroSystems, a Boeing contractor that builds the components of the 737 fuselage, such as the door plugs, since the accident.

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NASA officials on Wednesday held a media briefing, during which stakeholders revealed that confidence in Starliner’s ability to return the astronauts is waning. According to Ken Bowersox, associate administrator of the agency’s Space Operations Mission Directorate, teams are “getting more serious about evaluating our other options.”

The primary alternative, officials said, is to fly SpaceX’s upcoming Crew-9 mission with two astronauts rather than four, leaving room for Wilmore and Williams to hitch a ride when that mission concludes in February. They estimated that NASA will make a decision by mid-August.

“We could take either path,” Bowersox said.

Boeing and SpaceX representatives were not present on the call, the intention of which, NASA said, was to provide the agency’s perspective on the mission.

On its way up to the ISS, Starliner suffered two main issues that are giving crews pause over how to return the astronauts. A set of helium leaks that emerged on the spacecraft have since stabilized, according to NASA. However, the other issue, which involves five faulty reaction control system (RCS) thrusters on Starliner’s expendable service module, is still being evaluated.

Officials on Wednesday said ground testing of an identical thruster at White Sands Test Facility in New Mexico revealed that the problem is linked to a tiny Teflon seal on an oxidizer poppet, which controls the flow of propellant into the thruster. Teams theorize that the extreme heat the thrusters experienced during Starliner’s rendezvous with the ISS caused the Teflon to expand, inhibiting flow and causing them to fire at weaker-than-expected levels.

According to Steve Stich, who manages NASA’s Commercial Crew program, a July 27 Starliner hot fire test showed that the affected thrusters—with the exception of one, which has been deactivated—are now firing as expected. This has led engineers to hypothesize that the teflon seals contracted and are no longer blocking propellant from reaching the thrusters. Now, the task is to understand how and why.

Teams are working to better understand how those seals might behave during Starliner’s return trip, but there is not yet consensus on whether they are good to go. According to Bowersox and Stich, there is internal disagreement about returning the astronauts on Starliner versus Dragon, which was amplified with the discovery of the faulty teflon seal.

“We heard enough voices [on the program control board] that the decision is not clear,” said Bowersox.

The officials explained that Boeing, which on Friday asserted it has high confidence in Starliner, is viewing risk based on previous missions and flight performance, while NASA wants to understand the root cause of the issue before it has confidence in returning with crew. Ultimately, NASA administrator Bill Nelson will have the final say.

“Reasonable people could have different views on which path we should take,” said Bowersox, who acknowledged that the chance of an uncrewed return has risen in recent weeks. “I don’t think anyone has taken a view that you could prove is wrong or right.”

NASA will have until mid-August to decide whether the Dragon contingency plan should be put into action.

The ISS has two docking modules that are occupied by Starliner and SpaceX’s Crew-8 capsule, meaning Starliner would need to autonomously undock before Crew-9 launches on September 24. Crew-8 would then depart the space station with the crew of NASA’s Expedition 71, and the Crew-9 Dragon would take its place, leaving one docking port open for the next SpaceX cargo mission. Wilmore and Williams would stay for the duration of Crew-9, flying home with the two-person Expedition 72 crew in February.

The problem, though, is that Starliner’s flight software is not currently capable of an autonomous undocking despite having achieved the feat during an uncrewed mission in 2022.

For the CFT, the software was configured for a crewed undocking, as per the mission profile. Now, Boeing and NASA must modify the mission data load to reconfigure the system for an uncrewed undocking, which sources say could take up to one month. NASA said the spacecraft has built-in fault tolerance that would prevent it from colliding with the ISS should its thrusters not perform as expected during that maneuver.

The agency said it has been in daily communication with Wilmore and Williams and that the astronauts are prepared for whatever path it ultimately takes. If they stay along with Crew-9, they will assist personnel with scientific research, including spacewalks. Additional materials, such as spacesuits, would be sent up with the Dragon.

“Butch and Suni are ready to support whatever we need to do,” said Dana Weigel, manager of NASA’s ISS program.

Officials insist that despite the internal conflict around Starliner, the vehicle could still be used to return the astronauts in the case of a contingency on the ISS. In those scenarios, Bowersox said, NASA is willing to tolerate a higher level of risk—one that is jeopardizing teams’ ability to complete the CFT as intended.

The worst-case scenario, according to NASA, would be if the helium leak and thruster issues converge during Starliner’s deorbit burn, the maneuver that will place it back in Earth’s atmosphere. An unlikely combination of technical failures could impact the ability of the RCS thrusters to maintain the capsule’s orbital trajectory, though agency research predicts that it could complete the maneuver even with multiple failures.

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The post NASA: Starliner Astronauts May Not Return Until February appeared first on FLYING Magazine.

Wednesday is Day 2 of the NTSB hearing about the loss of a door plug from a Boeing 737 Max 9 in January after takeoff in Portland, Oregon.

According to Tuesday’s proceedings, sometimes the shoddy work was discovered and rectified before the aircraft was delivered. Sometimes it was not, as in the case of the 737 that was delivered to Alaska Airlines.

• READ MORE: NTSB Sanctions Boeing for Sharing Door Plug Blow Out Investigative Details

Boeing relies on contractor SpiritAeroSystems to build the fuselages. A representative from Spirit told the NTSB that the door plug for fuselage No. 8789, which was delivered to Alaska Airlines in fall 2023 and became ill-rated Flight 1282, was built at SpiritAeroSystems Malaysia and shipped to Wichita, Kansas, where it was installed in the fuselage, which was then shipped to the Boeing factory in Renton, Washington.

When it arrived at the factory, it was determined that the rivets in the assembly if the fuselage were substandard, and in order to replace them, the door plug had to be removed.

According to Elizabeth Lund, senior vice president/quality of Boeing Commercial Airplanes, when there is a need to replace a component such as a door plug, there is supposed to be a paperwork trail to indicate what needs to be done and who will do it, and then who has done it.

“We have still found no paperwork documenting the removal of 8789 left-hand door plug,” Lund testified to the NTSB on Tuesday.

Lund said the door plug was removed to replace a line of rivets that were not up to standard, and then it was put back into position so that the aircraft could be moved outside and its interior protected from the weather. The door plug was missing four crucial bolts.

• READ MORE: Boeing to Acquire Spirit AeroSystems in $8.3 Billion Deal

According to Boeing, under normal circumstances, the paperwork trail would let employees know the door plug had been reinstalled but the bolts had not been replaced. The paperwork would indicate the bolts had to be reinstalled before the aircraft could be delivered.

That was not the case here, according to testimony. The aircraft was delivered to Alaska Airlines in October 2023 and flew for approximately 100 flight cycles (takeoffs and landings) with the door plug kept in place by a series of small pins. There were two reports of crew noticing pressurization warning lights in the cockpit. The aircraft was supposed to go in for maintenance at the end of the duty day on January 5.

There were Spirit employees at the Boeing Renton plant, but according to testimony, communication between the Boeing and Spirit workers on the floor of the factory wasn’t good, and there was a lot of turnover at the facility because of low morale and early retirement of more experienced technicians due to COVID-19.

There were no serious physical injuries when the door plug blew out as the aircraft reached 16,000 feet, although seven passengers and a flight attendant were treated for injuries upon landing. The flight crew was praised for its skill, and aviation experts noted that had the aircraft been higher, the outcome would have been much worse.

NTSB Chair Jennifer Homendy offered an apology to the passengers and flight crew on behalf of the agency.

The decision to conduct the two-day hearing into the event is unprecedented. Within hours of the blowout, Alaska Airlines grounded its 737 Max 9s, and the FAA followed suit grounding the world fleet for 19 days while inspections were done to door plugs.

The post NTSB Grills Boeing Over Max 9 Door Plug Loss appeared first on FLYING Magazine.

NASA and Boeing are in the midst of the inaugural crew flight test (CFT) of Starliner, a semireusable vessel to the ISS under contract for agency service missions as soon as next year. But en route to the orbital laboratory, the spacecraft suffered several anomalies that have led teams to keep it on the ISS for further testing.

A preflight readiness review, during which crews would make a determination on Starliner’s return date, was expected last month but has since been pushed back, with no updates provided since last week.

NASA and Boeing last held a meeting to discuss Starliner’s issues with the media on July 25 and have insisted that the Boeing capsule will return the astronauts to Earth. However, as first reported by Ars Technica and confirmed by FLYING, it appears the space agency is considering enlisting SpaceX’s Dragon.

“NASA is evaluating all options for the return of agency astronauts Butch Wilmore and Suni Williams from the International Space Station as safely as possible,” a NASA spokesperson told FLYING. “No decisions have been made and the agency will continue to provide updates on its planning.”

The statement is a marked shift from the agency’s tone thus far, which has been adamant about Starliner safely returning Wilmore and Williams.

While SpaceX’s Dragon is not mentioned by name, it is the only vehicle in NASA’s ISS Commercial Crew rotation program. Steve Stich, who manages the Commercial Crew program, previously said that there were no discussions between the agency and SpaceX about using Dragon as an alternative. However, NASA in July issued a task award for SpaceX to study flying Dragon with six passengers, rather than the typical four.

In theory, the spacecraft could accommodate the four-person crew of SpaceX’s upcoming Crew-9 mission in addition to Wilmore and Williams. NASA is reportedly also considering flying Crew-9 with two crewmembers, leaving room for the two astronauts on the ISS.

The problem, though, is that Crew-9 on Tuesday was delayed from August 18 to September 24 to give Starliner teams more time to finalize a return plan.

Multiple independent sources also told Ars Technica that Starliner’s onboard flight software is not currently capable of completing an automated undocking from the ISS—despite the capsule completing that maneuver during an uncrewed flight test in 2022—and could take nearly a month to be updated.

If the report is accurate, the software issue would compound Starliner’s existing problems, the most consequential being a set of misfiring thrusters.

Five reaction control system (RCS) thrusters on the spacecraft’s service module fired at lower levels than expected during the trip to the orbital laboratory. The thrusters have been tested on orbit and are now operating at or near expected levels, according to NASA.

But the agency continues to wrap up ground testing at White Sands Test Facility in New Mexico, where an identical thruster is being evaluated. It appears crews do not yet have full confidence in the thrusters’ performance, as evidenced by the delay to the flight readiness review.

NASA continues to tout safety as its highest priority for the CFT, but there are certainly some politics at play.

On July 25, Stich said NASA would like to see Starliner return Wilmore and Williams during the CFT, implying that another crewed test could be required for certification if it doesn’t. The CFT is intended to be the final test flight, but Stich previously acknowledged that certification could take longer than originally expected.

Boeing last week released a statement appearing to publicly pressure NASA, reiterating its confidence in the vessel as evidenced by the extensive testing that has been performed since it docked at the ISS.

Already, Starliner’s inaugural service mission has been delayed from February to August 2025, adding to the almost decade of setbacks the program has suffered. Adding to the headache, Boeing has reportedly spent $1.6B on Starliner so far.

The manufacturer has plenty of incentive to push for Wilmore and Williams’ return on the spacecraft. But at the same time, a failed mission would likely torpedo the program, leaving stakeholders with a difficult decision.

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The aircraft, operating as Alaska Airlines Flight 1282, had just taken off from Portland International Airport (KPDX) in Oregon, and as it passed through 16,000 feet, the door plug blew off, resulting in rapid decompression. All 177 people on board the aircraft survived, although eight were injured by the loss of pressure that resulted in loose objects and parts of the cabin interior being turned into projectiles.

Last week the NTSB displayed the door plug that departed the aircraft. The door has been the subject of scrutiny in the agency’s materials lab.

• READ MORE: Boeing to Plead Guilty in DOJ 737 Max Crash Cases

The NTSB’s preliminary investigation revealed that four restraining bolts designed to hold the door plug in place were missing during the last flight. On two previous occasions the flight crews had reported a pressurization warning light had activated in the cockpit. Both times the crew notified maintenance about the issue. The aircraft was removed from over-water flights and scheduled for maintenance at the end of the day on January 5.

Boeing did not respond to FLYING’s inquiries by press time, although the aerospace manufacturer has been subpoenaed to appear at the hearing.

In response to the accident, the company initiated changes in the workplace to enhance safety culture that included the removal of several highly placed company officials. In March Boeing CEO Dave Calhoun announced he would step down at the end of the year. At the end of July Boeing announced Robert “Kelly” Ortberg will be the new CEO.

As previously reported by FLYING, the NTSB sanctioned Boeing, suggesting it had released nonpublic information into the investigation.

Alaska Airlines is a party to the investigation and offered a statement to FLYING.

• READ MORE: Boeing to Acquire Spirit AeroSystems in $8.3 Billion Deal

“We appreciate the importance of the investigative hearing being conducted by the National Transportation Safety Board (NTSB) into Alaska Airlines Flight 1282 and the ‘in-flight mid-exit door plug Separation,” Alaska Airlines said in the statement.  “This hearing is part of the NTSB’s established investigation to obtain additional information necessary to determine the facts, circumstances, and probable cause of the accident. Our participating safety and technical representatives remain committed to cooperating with the NTSB.”

The Alaska Airlines statement concludes that because this is an ongoing investigation, the company is limited in the details it can release.

“Safety is always our top priority at Alaska Airlines,” the company said. “We have full confidence in the safety of our operation and aircraft.”

The post NTSB to Conduct Hearing on Boeing 737 Max 9 Door Plug Incident appeared first on FLYING Magazine.

According to Boeing, Ortberg will begin in the position on August 8. He replaces Dave Calhoun, who earlier this year announced he was retiring. Calhoun had served as president and CEO since January 2020 and been on the Boeing board of directors since 2009.

Ortberg, 64, comes to the position with more than 35 years of experience in the aerospace industry. He recently served as president and CEO of Rockwell Collins, a position he held since 2013.

Ortberg was instrumental in the company’s integration with United Technologies and RTX. He holds a bachelor’s degree in mechanical engineering from the University of Iowa, has held numerous leadership positions in the aerospace industry, and is the former chair of the Aerospace Industries Association (AIA) board of governors.

• READ MORE: FAA Head Vows Increase in Boeing Oversight

“The board conducted a thorough and extensive search process over the last several months to select the next CEO of Boeing, and Kelly has the right skills and experience to lead Boeing in its next chapter,” said Steven Mollenkopf, chair of the board. “Kelly is an experienced leader who is deeply respected in the aerospace industry, with a well-earned reputation for building strong teams and running complex engineering and manufacturing companies. We look forward to working with him as he leads Boeing through this consequential period in its long history.”

The board also thanked Calhoun for his services, noting the past few years have been challenging for Boeing, beginning with the two 737 Max crashes in 2018 and 2019, respectively, resulting in the deaths of 346 people. The FAA ordered the grounding of the aircraft while the accidents were investigated. Boeing’s manufacturing and certification processes were called into question.

• READ MORE: Boeing Presents Quality Control Improvement Plan to FAA

The aerospace company announced it had worked through the issues and made changes to its manufacturing procedures to mitigate them. Then in January a 737 Max 9 operated by Alaska Airlines lost a door plug shortly after takeoff from Portland, Oregon, resulting in rapid decompression and minor injuries.

Next week the National Transportation Safety Board (NTSB) is scheduled to conduct an investigative hearing on the door plug loss.

In the meantime, the families of those killed in the crashes are campaigning for Boeing to face criminal prosecution and the U.S. Department of Justice to fine the company $24 billion, alleging criminal negligence and violating the 2021 agreement that allowed the company to previously avoid criminal charges.

The post Boeing Names New CEO to Lead Through ‘Consequential Period’ appeared first on FLYING Magazine.

The approval will allow SpaceX to stay on schedule with its Crew-9 mission to rotate astronauts at the International Space Station (ISS), which NASA officials on Friday said is planned for no earlier than August 18.

Falcon 9 was grounded by the FAA following a rare mishap during a July 11 launch of Starlink satellites, its first failure after a streak of more than 300 successful missions.

SpaceX on Thursday shed more light on the incident. The company traced the anomaly to a cracked sense line that created a liquid oxygen leak within the rocket’s second stage engine. This caused ignition fluid to freeze, preventing the engine from performing a burn that would have placed the satellites in a circular orbit.

Despite the issue, SpaceX said, the engine continued operating as intended through both of its planned burns, but all 20 satellites were lost.

The FAA swiftly grounded Falcon 9 as is standard whenever a launch does not go according to plan. SpaceX submitted a mishap report on the night of the anomaly.

Steve Stich, manager of NASA’s Commercial Crew program, said Friday that “SpaceX went above and beyond” in its assessment of the issue, working with NASA to develop a fault tree, review spacecraft telemetry, analyze video, and search for similar issues on other Falcon models.

The company has opted to remove the faulty sense line, which is redundant and not a part of the spacecraft’s safety system, for near-term Falcon 9 launches. It also agreed upon several corrective actions with the FAA that will be detailed in the coming days.

The FAA must still give a final sign-off for Crew-9 to launch, but the blessing to return to flight should allow SpaceX to meet its mission timeline. Stich on Friday said Crew-9 will launch no earlier than August 18 from Launch Complex 39-A at Kennedy Space Center in Florida, with the launch window extending into September.

The mission represents the fourth flight of this particular Falcon. It will launch SpaceX’s Crew Dragon on its 45th mission to the ISS. Once onboard, four crewmembers will spend six months conducting a range of experiments, including studying the physics of neutron stars and the behavior of wildfires on Earth.

The ISS’ two docking ports are occupied by SpaceX’s Crew-8 Dragon capsule and Boeing’s Starliner, the latter of which will need to make way for Crew-9. Complicating matters, however, is the unexpected extension of Starliner’s inaugural crew flight test (CFT), which has left astronauts Butch Wilmore and Suni Williams aboard the orbital laboratory for nearly two months.

Sources told Ars Technica’s Eric Berger that NASA is considering sending Crew-9 to the ISS with only two astronauts, theoretically making room for Wilmore and Williams to hitch a ride home on SpaceX’s Dragon rather than Starliner.

The scenario is one NASA hopes to avoid. Officials stopped short of calling it a requirement for certification but said that returning the astronauts home on Starliner rather than Dragon is “important” to the program’s goals. According to Stich, teams have finished an approximately monthlong test of Starliner’s thrusters and are working toward a flight readiness review, expected toward the end of next week.

However, Stich also said that NASA has officially handed over the Starliner’s first mission—which was double booked for early next year—to SpaceX. The flight, Starliner-1, will be pushed to no earlier than August 2025, while Falcon 9 and Dragon handle the agency’s tenth commercial crew rotation in February. Starliner-1 will again be double booked with SpaceX Crew-11.

Though SpaceX’s Falcon woes haven’t derailed Crew-9, they may shake up NASA’s busy ISS manifest. The agency is working toward an August 3 launch of Northrop Grumman’s Cygnus, followed by an August 13 Roscosmos launch. Crew-9 would be next, followed by SpaceX’s Polaris Dawn mission, originally scheduled for this month.

Beyond that, NASA wants to make a Soyuz ISS crew exchange in September, launch the Europa Clipper probe in October, and facilitate the Axiom-4 private astronaut mission in November.

Given the rapid turnaround following Falcon 9’s rare mishap, Boeing’s Starliner may be a larger culprit than SpaceX in any future delays.

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On Monday at EAA AirVenture in Oshkosh, Wisconsin, Piper announced that it renewed its distribution partnership with the aerospace titan, making Boeing its exclusive distributor for key parts and components through 2029.

“We are thrilled to grow this partnership with Boeing,” said Ron Gunnarson, vice president of sales, marketing, and customer support at Piper. “In the coming year, look for improved response time and dedicated, Piper-specific CSR assistance.”

Piper has relied on Boeing as its primary spares depot since 2010. The latter maintains an inventory of Piper parts worth over $22 million and, according to the company, has a fill rate north of 98 percent on forecasted parts. Boeing’s Dallas-Fort Worth warehouse complements Piper depots around the world, including in Europe, to enable international shipments.

Separately, Piper on Thursday announced that it delivered four Pilot 100i’s to the Florida Institute of Technology (FIT), part of a previously agreed order for eight aircraft. FIT is a key customer for the manufacturer, operating a fleet of only Piper aircraft: Archers, Seminoles, and Warriors.

“What makes all of this even more meaningful is that a dozen of our alumni working at Piper helped build these planes,” said John Nicklow, president of FIT. “It’s a high-flying example of the power of a Florida Tech education in action.”

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On Monday at the Farnborough International Airshow in the U.K., Wisk, in an expansion of its partnership with vertiport developer Skyports, announced an electric air taxi network that it hinted could be ready in time for the marquee event.

Wisk and Skyports in 2022 gave an early look at their vision for an eVTOL air taxi network, complete with infrastructure for vertical takeoff and landing, or vertiports. They will function much like heliports with electric aircraft chargers to juice up Wisk’s air taxi.

The partners now are working with the Council of Mayors of Australia’s South East Queensland (SEQ) region, with which Wisk has collaborated since 2022, to devise a network for the company’s Generation 6 model.

A prototype of the flagship design has a range of 90 sm (78 nm) with reserves and charge time of 15 minutes. Like designs from competitors Archer Aviation and Joby Aviation, the Gen 6 features tilting propellers that aid in both vertical and forward flight. Wisk, though, is one of a handful of firms in the industry looking to fly autonomously at launch. It projects a commercial rollout will happen by the end of the decade.

Wisk and Skyports will pick out hubs for the air taxi across the SEQ region, home to an estimated 4 million and growing. The partners said they will study regional travel patterns, conduct feasibility studies, and speak with local communities about what to expect from the service.

They also noted that the region is already preparing for the 2032 Olympic and Paralympic games, saying they expect to plan out air taxi infrastructure in time for the big event.

“We’re excited to see this evolving industry bring high-value local jobs to SEQ and support improved services like medical and tourism,” said Scott Smith, CEO of the SEQ Council of Mayors. “To secure our place as a global destination, we must be at the forefront of adopting emerging technologies.”

Wisk is developing a similar network in Japan in partnership with flag carrier Japan Airlines.

It likewise has plans for the U.S. in the Greater Houston region of Texas and is working toward bringing the Gen 6 to Long Beach, California. Officials in Los Angeles are preparing for the introduction of air taxis ahead of the 2028 Olympic and Paralympic Games, though it is unclear if Wisk will meet that deadline.

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