For the public, those were the first words heard from NASA astronauts Butch Wilmore and Suni Williams—the crew of the space agency’s Boeing Crew Flight Test (CFT)—since they arrived at the orbital laboratory more than one month ago for an intended eight-day stay.

The Earth-to-orbit call between crew and NASA command was live streamed on the agency’s website. The event answered appeals from members of the media, made during a previous press conference, to see the astronauts on camera as concerns with Boeing’s CST-100 Starliner—which brought them to the ISS—continue to linger.

The spacecraft is contending with two key problems: helium leaks and deactivated or underperforming thrusters. The issues are concentrated within the spacecraft’s service module, which aids in maneuvers such as docking and undocking with the ISS.

NASA and Boeing have indicated that Starliner has more than enough helium to make it home but are continuing to assess the root cause of the leaks. During a hot fire test after docking, four out of the five affected thrusters performed as expected. The fifth was deactivated for the remainder of the mission.

Williams and Wilmore recounted their trip to the space station and the moment they realized that Starliner’s thrusters were not firing at full power. They also sang the spacecraft’s praises, with Wilmore even saying he was tempted to award his first perfect rating for its handling performance.

Separately, NASA and Boeing representatives held a press conference to provide the latest on ongoing ground thruster testing at White Sands Test Facility in New Mexico. Officials again did not provide a firm return date for Wilmore and Williams. But Steve Stich, manager of NASA’s Commercial Crew program, estimated that testing could wrap up by the end of the month, after which point teams will iron out a timeline.

Engineers hope to conduct as many evaluations as possible while the semireusable spacecraft, designed to survive 10 missions, is in orbit. Starliner’s service module, the expendable component of the spacecraft, will be jettisoned and lost as it reenters Earth’s atmosphere.

Astronauts Phone Home

Williams and Wilmore on Wednesday made their long-awaited first appearance on camera since arriving at the ISS on June 6, recounting the CFT’s progress so far.

“Launch was spectacular,” Wilmore said, adding that the spacecraft performed “unbelievably well” during operational capability checks.

However, on the second day of their journey to the ISS, the astronauts could tell something was amiss. As Starliner approached the orbital lab, a total of five reaction control system (RCS) thrusters on its service module either turned off or did not fire at intended strength. Williams and Wilmore commandeered the capsule manually for about one hour as teams on the ground assessed the issue.

“From that point on, you could tell that the thrust was degraded,” Wilmore said. “But it was still impressive.”

Even with less-than-optimal performance, the thrusters completed what Wilmore described as a perfect maneuver as they navigated the final 10 meters to dock Starliner with the space station.

According to Williams, the astronauts talk with mission crews once per week to share and analyze the data they’ve collected. She highlighted the capsule’s ability to serve as a “safe haven” in the event of an ISS evacuation—a role it fulfilled last month after a Russian satellite broke up in orbit.

“We are having a great time here on the ISS,” said Williams. “I’m not complaining, Butch isn’t complaining, that we’re here for a couple extra weeks.”

One question NASA and Boeing have received is whether Starliner could bring Williams and Wilmore home right now. Officials insist it could, but only in an emergency situation that would require the ISS to be evacuated. The astronauts were asked about their confidence level in that scenario.

“I feel confident that, if we had to—if there was a problem with the International Space Station—we could get in the spacecraft and undock, talk with our team, and figure out the best way to come home,” said Williams.

She later added, “I have a real good feeling in my heart that the spacecraft will bring us home no problem.”

Wilmore said he and his crewmate “trust the tests we are doing are the right ones we need to do to get us the right answers, to give us the data we need to come back,” adding that they are “absolutely ready” for a return based on current engineering data.

NASA could send a SpaceX Crew Dragon capsule—which has completed all eight ISS Commercial Crew rotation missions to date—to retrieve the astronauts should Starliner’s issues persist. On Wednesday, Stich said the space agency has not yet opened those discussions with SpaceX, though he did not rule out the possibility.

The astronauts also described their view of Hurricane Beryl from space, saying that their families—who live in Texas and were in the storm’s path—are doing well. Wilmore said he is “90 percent sure” he could see the storm forming off the West coast of Africa days before it was named.

The 20-minute call concluded with some zero-gravity backflips by Williams and a big, smiling thumbs-up from Wilmore.

NASA, Boeing Share More Info

Stich and Mark Nappi, vice president and general manager of Boeing’s Commercial Crew program, addressed the media following the astronauts’ remarks.

According to Stich, Starliner will need to undock before mid-August, when SpaceX’s Crew-8 team swaps with the incoming Crew-9. Williams and Wilmore will need to return a few days before the Crew-9 launch window opens. Starliner remains a “go” for return in an emergency scenario, officials said. But they prefer to wait until ground testing is complete before attempting a by-the-books return,

Stich estimated that hot fire testing at White Sands could “optimistically” wrap up by the end of July, though it could be extended. Teams are working toward a nominal return flight readiness review, standard for crew rotation missions, that would give the green light to finish the mission as planned. 

Should more time be needed, NASA is in the process of approving a 45-day extension of the CFT, which is contingent on the health of Starliner’s batteries. According to Stich, those systems have shown no sign of wear and tear.

The goal of the test campaign is to recreate the firing pattern of one of Starliner’s faulty thrusters using an identical thruster—designed for a future mission—on the ground. Hot fire testing began on July 3, but Stich said crews have so far been unable to achieve the temperatures experienced by the thruster in orbit. Engineers believe the unusual firing pattern could be due to excess heat.

Teams will then attempt to predict how the thrusters might behave as Starliner undocks and flies home. Based on their learnings, they could modify the spacecraft’s flight path, deactivate certain thrusters, or fire them at different rates. Williams and Wilmore are capable of piloting Starliner manually if issues arise.

At the same time, Stich said White Sands personnel are evaluating the service module for Starliner’s inaugural crew rotation mission, Starliner-1, scheduled for February. The current service module has contended with a series of helium leaks, for which crews are attempting to uncover the root cause. Starliner-1’s service module won’t be redesigned, but Nappi said future models could incorporate changes based on the testing at White Sands.

The Outlook

Extended ISS stays are not necessarily uncommon, and the space station is designed to accommodate crew for months at a time if needed.

NASA astronaut Frank Rubio, for example, set a U.S. spaceflight record when his planned six-month mission was nearly doubled to 371 consecutive days aboard the orbital laboratory. Unlike Starliner, the Russian Soyuz capsule that ferried Rubio to the ISS was quickly ruled out as an emergency return vehicle, lending credence to the idea that Boeing’s issues are less severe.

However, NASA and Boeing face the added pressure of certification after close to a decade of delays to the Starliner program. In a prior press conference, Stich acknowledged that NASA and Boeing “understand it’s going to take a little bit longer” to certify Starliner than originally planned.

On Wednesday, the Commercial Crew manager said teams will decide between Starliner-1 or SpaceX Dragon’s Crew-10—which are booked for the same February launch window—once the CFT ends and postflight analysis is complete. The longer that takes, he said, the more likely it is that SpaceX will take over the mission.

Nappi agreed with that assessment, citing the need to understand and fix Starliner’s helium leaks as the biggest obstacle to certification.

NASA and Boeing said Wilmore and Williams will make one more Earth-to-orbit call before they depart the ISS, with more details to come.

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During a media briefing on Friday, NASA and Boeing representatives said the astronauts’ return to Earth will come after ground testing at the White Sands Test Facility in New Mexico is complete. Teams are working to re-create some of the issues experienced by the reusable spacecraft during its inaugural crewed flight to the orbital laboratory.

According to Steve Stich, manager of NASA’s Commercial Crew program, Starliner was originally deemed safe for a stay as long as 45 days on the ISS. Crews are in the process of extending its battery life, which Stich said will keep the risk level manageable for another 45 days, at least.

However, he conceded that NASA and Boeing “understand it’s going to take a little bit longer” to certify Starliner than previously planned. The spacecraft is scheduled to fly its first service mission, Starliner-1, early next year. Officials said SpaceX’s Crew Dragon, which has completed all eight commercial crew rotation missions to the ISS to date, could take that slot.

“We’re not in any rush to come home,” Stich said Friday. “The risk for the next 45 days is essentially the same as for the first 45 days.”

Added Ken Bowersox, associate administrator of NASA’s Space Operations Mission Directorate: “We have the luxury of time.”

Stich, Bowersox, and Mark Nappi, the manager of Boeing’s commercial crew program,  reiterated that “engineering data suggests” Starliner is safe to return Wilmore and Williams to Earth in the event of an emergency.

Officials also reported that the spacecraft is in “good shape” despite two lingering issues—a set of helium leaks and faulty thrusters.

A total of five helium leaks have sprung up on Starliner’s service module, which makes tiny maneuvers to the spacecraft to assist in docking and keep it in orbit. After testing the helium manifolds earlier this month, NASA found that leak rates had declined. Stich on Friday said those rates have not changed.

The other issue involves the service module’s thrusters, some of which did not fire at full strength en route to the ISS. These were also assessed earlier this month, and Stich said performance on all thrusters is between 80 and 100 percent.

It appears the thrusters are the main factor necessitating a longer mission for Starliner. As soon as Tuesday, engineers will begin testing an identical component at White Sands to re-create the firing pattern of one of the in-orbit thrusters. Officials said the campaign is expected to last several weeks and could be extended.

According to Nappi, teams want to keep Starliner in space for the evaluations because they could inform additional in-orbit tests or a modification of the spacecraft’s undocking procedure. He said crews do not yet understand the issue well enough to fix them permanently and that it would be “irresponsible” not to use additional time to conduct testing. Starliner’s crew module is reusable for up to 10 missions, but the service module will be jettisoned during the CFT.

Nappi said he has been in contact with Wilmore and Williams and that they remain in good spirits, describing Starliner as “pristine and precise.” The astronauts are able to communicate with their families daily and according to officials are not “stranded.”

On Wednesday, Starliner got another real-life test when an in-orbit satellite breakup created a debris field that hurtled toward the ISS. Wilmore and Williams tested the spacecraft’s ability to act as a “safe haven” in the case of a contingency on the space station, getting inside, powering it up, and sealing the hatch. They remained inside for an hour and according to officials were prepared to initiate an undocking if necessary.

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On Wednesday morning, the autonomous, semireusable space capsule—intended for 10 service missions to the International Space Station (ISS) under a multibillion contract between the aerospace manufacturer and NASA—finally lifted off with humans for the first time.

The long-delayed mission, called the Boeing Starliner Crew Flight Test (CFT), will take NASA astronauts Butch Wilmore and Suni Williams to the orbital laboratory, where they will conduct an array of tests and evaluations of the spacecraft, its systems, and equipment.

The CFT is expected to be Starliner’s final flight test, demonstrating its capabilities with astronauts on board before NASA moves to certify it for Commercial Crew rotation missions to the ISS. The first of these, Starliner-1, could take place as early as next year.

An initial CFT launch attempt on May 6 was scrubbed, and the mission was postponed several times before finally taking flight. But Wilmore and Williams are now well on their way to the space station, where they are expected to dock Thursday at 12:15 p.m. EDT.

We Have Liftoff

Starliner lifted off from the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday at 10:52 a.m. EDT as teams had planned.

Carrying the capsule into orbit was United Launch Alliance’s (ULA) Atlas V rocket, which is making its 100th flight. Atlas V, when stacked together with Starliner, stands over 170 feet tall and generated some 1.6 million pounds of thrust at liftoff.

The liftoff represented the first time humans have hitched a ride on either Starliner or Atlas V. Williams became the first woman to fly on the maiden voyage of a crewed spacecraft.

After achieving Max Q—the moment the rocket faces the greatest amount of pressure as it climbs through the atmosphere—Starliner successfully separated from Atlas V at suborbit, just under 15 minutes into the mission. From this point on, the astronauts will be on their own.

About half an hour into the mission, Starliner executed a successful insertion burn to place it in stable orbit, from which the capsule will embark on an approximately 24-hour journey to the ISS. The spacecraft will dock with the orbital laboratory’s Harmony module Thursday afternoon, and Williams and Wilmore will disembark to join the crew of NASA’s Expedition 71 for a weeklong stay.

Setting the Stage

Throughout the CFT, the astronauts will work to prepare Starliner for certification.

The performance of equipment such as suits and seats was assessed during prelaunch and ascent. As Starliner rendezvous with the space station, the crew will conduct further testing of life support equipment, manual and automated navigation systems, and thruster performance in the scenario of a manual abort. While capable of flying on its own, the capsule can be commanded manually, and crews have failsafes at their disposal at different points in the flight path.

After assessing Starliner’s autonomous docking capabilities and the opening and closing of its hatch, the astronauts will configure the spacecraft for its stay and move emergency equipment into the ISS. Once they are settled, teams will perform checks of displays, cargo systems, and the vehicle itself.

Williams and Wilmore will also try to prove that the capsule could serve as a “safe haven” in the event of depressurization, fire, or collision with debris impacting the orbital laboratory.

On their return trip, the astronauts will briefly test out Starliner’s manual piloting capabilities. As it approaches Earth’s atmosphere, the capsule will slow from its orbital velocity of 17,500 mph and touch down in one of four locations in the Western U.S., using a combination of parachutes and airbags.

A Calculated Risk

If all goes according to plan, Starliner could launch on its first Commercial Crew rotation mission for NASA in the first half of next year. However, the space agency, Boeing, and ULA are taking a calculated risk with the mission.

A helium leak traced to one of the 28 reaction control system thrusters on Starliner’s service module—which helps maneuver the capsule while in orbit—is responsible for a few of the spacecraft’s recent setbacks. NASA describes the leak as small and stable.

But in a scenario Steve Stich, who manages the Commercial Crew program, described as “a pretty diabolical case, where you would lose two helium manifolds in two separate [thrusters]” that are next to one another, Starliner could be unable to perform a deorbit burn. That’s the maneuver that allows it to slow down from orbital speeds as it reenters the atmosphere.

NASA estimated the likelihood of this occurring at 0.77 percent. As a contingency, it and Boeing developed a modified deorbit burn procedure which they say has been tested in a simulator by Williams and Wilmore.

What It Means

There’s a lot riding on the Starliner CFT’s success.

For Boeing, which rakes in billions every quarter, the more important impact may be reputational rather than financial. The company has come under fire in recent months for its internal safety processes, and successfully flying two humans to the ISS and back could help ease the pressure.

For NASA, Starliner may be instrumental in achieving the agency’s goals.

To date, all eight Commercial Crew rotation missions have been flown by SpaceX’s Crew Dragon, which like Starliner is a reusable capsule for up to seven passengers. SpaceX signed its own multibillion-dollar contract with the space agency at the same time as Boeing and has since extended it multiple times, without failing to complete a mission.

But NASA wants an alternative to Dragon in the case of a contingency, such as the one that stranded astronaut Frank Rubio on the ISS for nearly a year—and helped him set a U.S. spaceflight record in the process. The space agency made sure to commemorate Rubio’s achievement, but it wants to avoid a similar situation recurring. By keeping two reusable spacecraft in its fleet, it could have one ready to retrieve a crew in case the other fails.

Should Starliner enter NASA’s Commercial Crew rotation, it will alternate six-month missions to the ISS with Dragon.

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The mission, which has faced a series of setbacks since an initial launch attempt was scrubbed on May 6, is now targeted for 10:52 a.m. EDT on Wednesday, with a backup launch window available Thursday.

The Starliner CFT is intended to be the spacecraft’s final test flight before NASA moves to certify it for service missions to the ISS, the first of which could take place next year. To date, all eight Commercial Crew rotation missions to the orbital laboratory have been flown by SpaceX’s Crew Dragon. 

The company signed its own multibillion-dollar contract with the space agency at the same time as Boeing but has already cemented itself as an invaluable partner. The same cannot be said for the aerospace giant, which has flown Starliner to the ISS just once.

CFT launch attempts have been delayed or scrubbed due to a litany of issues. First, it was a faulty pressure regulation valve on United Launch Alliance’s (ULA) Atlas V launch vehicle, which will carry Starliner into orbit. Then, crews discovered a small helium leak on Starliner itself, involving one of the 28 reaction control system thrusters on its service module. These small engines use helium to make minor maneuvers and keep Starliner in orbit.

NASA and Boeing have since described the leak as stable but have opted not to repair it, which would require Starliner to be unstacked from Atlas V and could take months. However, in investigating the root cause of the leak, crews discovered what the space agency described as a “design vulnerability” in the capsule’s propulsion system.

In a scenario NASA estimates has a likelihood of about 0.77 percent, the original leak could combine with an adjacent leak to prevent Starliner from performing a deorbit burn. That’s the maneuver that returns a spacecraft to Earth’s atmosphere following its mission.

All of this work identifying and assessing risk pushed the CFT back to Saturday. But yet another problem forced a cancellation of the launch just a few minutes before takeoff—and made a second go-around on Sunday infeasible.

According to the Starliner team, the issue is again on ULA’s side of things.

During the countdown, ground support equipment on the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida experienced issues, which crews traced to a power supply unit on one of three chassis on Atlas V’s Centaur upper stage. The power supply unit indirectly powers Centaur’s topping valves during the launch sequence, and all three chassis must be running in order for the countdown to be completed.

According to Tory Bruno, CEO of ULA, the chassis with the faulty power unit was quickly replaced. The new equipment has been retested and was functioning normally as of Sunday. NASA and Boeing added that they did not observe any physical damage to Starliner or Atlas V, and crews will perform a “full failure analysis” to determine what went wrong.

NASA astronauts Butch Wilmore and Suni Williams, Starliner’s first human passengers, remain in quarantine at Kennedy Space Center. If all goes according to plan, Wilmore and Williams will dock with the ISS later this week. There, they will spend about one week performing tests of Starliner’s systems as NASA prepares for the program’s next step: certification.

After that, Starliner would begin alternating six-month Commercial Crew rotation missions with SpaceX’s Dragon.

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NASA and Boeing on Wednesday announced that the Starliner Crewed Flight Test (CFT), intended to be the spacecraft’s final dress rehearsal before the agency certifies it for service missions, is a “go” to proceed for 12:25 p.m. EDT on Saturday, June 1.

However, Starliner engineers during a press conference last week said that a design flaw with the spacecraft’s propulsion system gives the capsule a 0.77 percent chance of being unable to perform a deorbit burn after it returns from the ISS. A deorbit burn, in which the vehicle reverses direction and fires its orbital maneuvering engines to slow itself, is used to maneuver a spacecraft back into Earth’s atmosphere.

NASA, Boeing, and launch provider United Launch Alliance, a joint venture between Boeing and Lockheed Martin, are taking a calculated risk with the launch attempt following years of delays to the Starliner program. The setbacks have resulted from a combination of issues involving the spacecraft’s software, propulsion system, and parachutes.

Boeing and rival SpaceX each have multibillion-dollar contracts with the space agency to provide crew rotation services. But all eight missions to the ISS to date have been flown using SpaceX’s Crew Dragon, which like Starliner is a reusable capsule designed to accommodate up to seven passengers.

Starliner in 2019 and 2022 attempted two uncrewed test flights to the ISS, the first aborted and the second successful.

The capsule’s first crewed mission has been delayed a number of times since an initial launch attempt scheduled for May 6 was scrubbed due to an issue with ULA’s Atlas V launch vehicle. Following that setback, engineers discovered a small helium leak on the Starliner capsule itself, tracing it to one of 28 reaction control system thrusters on the spacecraft’s service module.

“This is a high-pressure system, and helium is a very small, tiny molecule, and it tends to leak,” said Steve Stich, manager of NASA’s Commercial Crew program, last week. “This particular leak, I don’t think it implicates the design of the seal or the flange. It’s just maybe a defective part.”

Rather than replace the faulty valve, which would involve removing Starliner from the Atlas V rocket and could take several months, crews decided to try and better understand the flaw.

According to Stich, Starliner could actually weather a complete rupture in the valve’s seal, even if additional helium leaks spring up elsewhere.

“We could handle this particular leak if that leak rate were to grow even up to 100 times,” he said.

The leak is now described as stable, and Stich noted that SpaceX’s Dragon has also encountered leaks, which did not impact operations. But in the course of investigating the issue, teams uncovered yet another problem.

“We found a design vulnerability…in the [propulsion] system as we analyzed this particular helium leak, where for certain failure cases that are very remote, we didn’t have the capability to execute the deorbit burn with redundancy,” said Stich.

In what Stich described as “a pretty diabolical case where you would lose two helium manifolds in two separate doghouses, and then they have to be next to each other”—referring to the aforementioned 0.77 percent figure—Starliner could be unable to perform a deorbit burn. Engineers said they have come up with a contingency plan that has already been tested by NASA astronauts Suni Williams and Butch Wilmore in a Starliner simulator.

“We have multiple redundancies in our system,” Mark Nappi, vice president of Boeing and program manager for Starliner, said last week. “We have a case here that’s extremely remote that we missed. And if there are more out there, they’re going to be in that same category of extremely remote.”

Though the issue hasn’t entirely gone away, Starliner teams appear committed to a launch on Saturday.

NASA, Boeing, and ULA on Wednesday completed a Delta-Agency Flight Test Readiness Review, determining that all Starliner systems, facilities, and teams are ready for launch. On Thursday, crews rolled Atlas V and Starliner back to the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida, further signaling their intent to move forward with the attempt.

NASA will provide live coverage of the mission on its website, app, and YouTube channel. If all goes according to plan, Starliner, carrying Wilmore and Williams, will dock to the ISS’s Harmony module Sunday afternoon. The astronauts would then spend about one week on the orbital laboratory, where they will test the capsule’s systems in order to advance the certification process.

NASA hopes to get Starliner into its Commercial Crew rotation with the Starliner-1 service mission, scheduled for no earlier than 2025. After that, it would alternate six-month missions to the ISS with SpaceX’s Dragon.

U.S. Space Force meteorologists on Friday said there is a 90 percent chance that weather conditions will meet the criteria for a safe launch. Should the attempt be scrubbed again, backup launch windows are scheduled for Sunday, June 2, Wednesday, June 5, and Thursday, June 6.

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After postponing the previously announced May 25 launch attempt of the Starliner CFT on Tuesday, NASA on Wednesday said that it, Boeing, and launch provider United Launch Alliance, a joint venture between Boeing and Lockheed Martin, are targeting no earlier than Saturday, June 1, at 12:25 p.m. EDT for the next attempt. Additional launch windows include Sunday, June 2, Wednesday, June 5, and Thursday, June 6.

The postponement is the latest in a string of delays that have impacted the mission—and plagued the Starliner program more broadly—for years. An initial launch attempt was scrubbed hours before takeoff on May 6.

The setback follows the discovery of what NASA and Boeing described as a small helium leak on Starliner’s service module, which is designed to power and maneuver the autonomous spacecraft on its journey to the ISS.

According to NASA, Starliner teams have been meeting extensively to identify a new launch date, but further work remains. The agency said the current leak remains stable but that crews are now conducting follow-on performance and propulsion system assessments “to understand potential helium system impacts on some Starliner return scenarios.”

NASA will also perform a Flight Test Readiness Review to recap the work that has been done since May 6 and explain the rationale for attempting the next launch. A date for that review has not been identified but will be announced once selected, it said.

“It has been important that we take our time to understand all the complexities of each issue, including the redundant capabilities of the Starliner propulsion system and any implications to our Interim Human Rating Certification,” said Steve Stich, manager of NASA’s Commercial Crew program. “We will launch [astronauts] Butch [Wilmore] and Suni [Williams] on this test mission after the entire community has reviewed the teams’ progress and flight rationale at the upcoming Delta Agency Flight Test Readiness Review.”

NASA views Starliner as an alternative to SpaceX’s Crew Dragon for missions to low-Earth orbit. Dragon has flown each of the space agency’s eight Commercial Crew rotation missions, ferrying astronauts to and from the ISS, and will facilitate the upcoming Crew-9 mission scheduled for August.

But NASA wants to keep two reusable spacecraft in its fleet in case of a contingency, such as the incident that stranded astronaut Frank Rubio on the orbital laboratory for six months.

Boeing and SpaceX in 2014 each signed multibillion-dollar contracts with the agency to secure test flights and several Commercial Crew missions for their respective vessels. SpaceX has since expanded its arrangement multiple times, while Starliner—which is under contract for six flights—has languished in the development phase.

The Starliner CFT is intended to be the spacecraft’s final test flight before NASA certifies it for Commercial Crew rotation flights. If all goes according to plan, the spacecraft’s first commercial mission to the ISS, Starliner-1, could take place next year. But the delays continue to pile up.

The mission was initially scrubbed due to an oscillating pressure regulation valve on ULA’s Atlas V rocket, which will send Starliner into orbit. The partners set a new target launch date of May 10, later revising it to May 17 to give crews additional time to resolve the issue.

Then, last week, teams discovered a new problem—this time involving a helium leak on one of the Starliner capsule’s 28 reaction control system thrusters. Helium allows the thrusters to fire and make minor maneuvers in orbit. As a result, the launch was pushed to no earlier than Tuesday, a timeline that was then revised yet again to Saturday.

With Wednesday’s announcement, the partners are now nearly one month behind schedule, placing the Starliner team in a bind. On one hand, the safety of the astronauts must be prioritized. But on the other, there is some pressure to launch sooner rather than later.

As Ars Technica’s Stephen Clark notes, the ISS docking schedule gets a bit crowded after July, so there is some pressure for Starliner teams to launch sooner rather than later. In addition, Space Launch Complex 41 at Cape Canaveral Space Force Station in Florida—from where Starliner will launch—is used by ULA for other Atlas V and Vulcan Centaur launches.

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SpaceX on Saturday unveiled its first-generation extravehicular activity (EVA) spacesuit, which will be donned by astronauts aboard the Polaris Dawn mission, scheduled for no earlier than this summer. Polaris Dawn—a five-day, four-person orbital mission to research human health both in space and on Earth—is the first of three potential human spaceflights under the Polaris Program.

SpaceX and entrepreneur Jared Isaacman, who founded the program in February 2022, held a discussion accompanying the announcement on social media platform X, formerly Twitter, which SpaceX CEO Elon Musk acquired in October..

While the mission has no firm launch date, SpaceX on Saturday confirmed that Polaris Dawn would be the next crewed mission the company will fly.

What Is Polaris?

The Polaris Program is the brainchild of Isaacman, the billionaire CEO of integrated payments provider Shift4 who is also a pilot and astronaut, with more than 7,000 flight hours and multiple experimental and ex-military aircraft ratings. Isaacman in 2012 founded Draken International, a private air force that trains pilots for the U.S. Armed Forces.

Isaacman purchased flights from SpaceX in February 2022 to launch the program and is funding Polaris Dawn himself.

Named after the constellation of three stars more commonly known as the North Star, or Polaris, the program comprises three potential missions, one for each star. The effort aims to rapidly advance human spaceflight capabilities with an eye toward future missions to the moon, Mars, and beyond. Simultaneously, it will raise funds and advance research into issues facing humanity on Earth, such as cancer.

Polaris Dawn, the first of the three missions, was announced in 2022 and expected to fly later that year. It has since been delayed multiple times, most recently from February to mid-2024, due in part to SpaceX’s development of the specially designed EVA spacesuits.

Polaris Dawn and a second mission without a timeline, simply called Mission II, will be flown using SpaceX’s Falcon 9 rocket and Crew Dragon capsule. Both vehicles are already in use by NASA and a handful of commercial customers, such as Axiom Space.

Falcon 9, a reusable two-stage rocket, is the world’s first orbital class reusable rocket and has been lauded for driving down launch costs in flying 330 times. Crew Dragon, which is capable of carrying up to seven passengers, in 2020 restored NASA’s ability to ferry astronauts to and from the International Space Station (ISS) with the first Commercial Crew rotation mission. It has flown a total of 46 missions, visiting the ISS on 42.

Polaris is expected to culminate in a third mission comprising the first crewed flight of SpaceX’s Starship, the largest and most powerful rocket ever built. Like Falcon 9, the spacecraft is designed to be fully reusable and has so far attempted three orbital test flights, each more successful than the last.

Isaacman has been outspoken about Polaris’ aim to make human spaceflight accessible to all. The new SpaceX suits, for example, are designed to fit a range of body types and accommodate all spacewalkers.

At the same time, the billionaire aviator is focused on solving problems on Earth. Since its founding, Polaris has worked closely with St. Jude Children’s Research Hospital and helped fund research into childhood cancer.

Civilians in Space

Polaris Dawn is notable for its four-person crew, which includes the first SpaceX employees expected to actually reach space.

Mission specialist Sarah Gillis oversees the company’s astronaut training program, while mission specialist and medical officer Anna Menon manages crew operations. Gillis, trained to be a classical violinist, joined SpaceX in 2015, while Menon is a seven-year NASA veteran. But both have been part of past Crew Dragon flights. Menon in particular was influential in developing Dragon’s crew and emergency response capabilities.

Joining the SpaceX employees will be pilot Scott Poteet, a retired Air Force lieutenant colonel with more than 3,200 flying hours in the F-16, A-4, T-38, T-37, T-3, and Alpha Jet.

Isaacman himself will serve as Polaris Dawn mission commander, a role he also filled for  SpaceX’s 2021 Inspiration4 mission: the first all-civilian mission to space. Poteet, who previously served in roles at Isaacson’s companies Shift4 and Draken, was mission director for that flight, which raised $250 million for St. Jude.

To prepare for Polaris Dawn, crewmembers lived inside the decompression chamber at NASA’s Johnson Space Center in Houston for two days, summited the 16,800-foot peak of Illinizas Norte volcano in Ecuador, and experienced 9 Gs of force while training on three different kinds of fighter jets.

The mission will launch from Launch Complex 39A at Kennedy Space Center in Florida. The crew will spend up to five days in orbit, performing about 40 experiments and testing of hardware and software. Like Inspiration4, it is a charitable effort, with the goal of raising additional funds for St. Jude.

“Fifty or 100 years from now, people are going to be jumping in their rockets, and you’re going to have families bouncing around on the moon with their kids at a lunar base,” said Isaacman in an article on the St. Jude website. “If we can accomplish all of that, we sure as heck better tackle childhood cancer along the way.”

Polaris Dawn aims to fly higher than any SpaceX Dragon mission to date, a height that hasn’t been reached since the end of the Apollo program half a century ago.

The crew will also attempt to reach the highest Earth orbit ever flown. Isaacman during the discussion on X said the mission will target an apogee of 1,400 kilometers, or about 870 miles, more than double the orbital height reached by Apollo 17. That orbit would place the crew just inside the Van Allen radiation belt, where it hopes to research effects of spaceflight and space radiation on human health.

“The benefit of being at this high altitude is that we can better understand the impacts of that environment…on both the human body…as well as on the spacecraft,” said Menon during the discussion on X.

Suit Up

The Dragon capsule will complete seven elliptical orbits until reaching its apogee before descending to a circular orbit at about 700 kilometers (435 miles). At that altitude, crewmembers will attempt the first commercial spacewalk. It would also be the first time four astronauts have been exposed to the vacuum of space at the same time, according to SpaceX.

The spacewalk will mark the first use of SpaceX’s EVA spacesuit in low-Earth orbit, a key milestone that is expected to inform future iterations of the design for long-duration missions.

It’s an evolution of SpaceX’s Intravehicular Activity (IVA) suit that has been modified to enable both intra and extravehicular use. In other words, personnel won’t need to change clothes when moving from the confines of the spacecraft to the harsh environment of space.

The EVA suit adds greater mobility, seals and pressure valves, a helmet camera, and textile-based thermal material, which regulates suit temperature and can be controlled using a dial. Boots were constructed from the same thermal material used to shield Falcon and Dragon from exposure.

“There was a lot of work on both the materials of the suit, developing a whole new layer that we needed to add for thermal management as well as looking at the thermal condition for the crewmembers themselves, and making sure that they were at a comfortable temperature inside the suit,” said Chris Drake, manager of SpaceX’s spacesuit team, on Saturday.

The 3D-printed helmet incorporates a new visor designed to reduce glare as well as a state-of-the-art, heads-up display (HUD). The HUD is active only during spacewalks and displays spacesuit pressure, temperature, and humidity, as well as a mission clock to track how long the astronauts are exposed to the vacuum of space.

Already, SpaceX is developing a second-generation EVA suit for missions to the moon and Mars. It estimates that millions of suits will be required to one day build a lunar base or Martian city.

“This is important because we are going to get to the moon and Mars one day, and we’re going to have to get out of our vehicles and out of the safety of the habitat to explore and build and repair things,” Isaacman said during the discussion on X.

The Dragon capsule has also required modifications to prepare for the landmark spacewalk. SpaceX on Saturday said a structure called “Skywalker” has been attached near the capsule’s hatch to act as a mobility aid. Handrails and foot rails have been installed inside the spacecraft, with a ladder interface added to the hatch opening.

SpaceX also installed a cabin pressurization system that allows the interior of the capsule to withstand the vacuum of space as air is sucked out during the spacewalk. A repressurization system will stabilize it once the astronauts return.

Why It Matters

In addition to achieving the first commercial spacewalk and the highest orbital altitude ever recorded, Polaris Dawn hopes to test Starlink laser-based communications in space for the first time. Data from the test could help develop space communications for future missions.

In addition, Polaris and SpaceX selected 38 scientific experiments from 23 partner institutions—including NASA, the U.S. Air Force Academy, and Embry-Riddle Aeronautical University—intended to advance the understanding of human health in space and on Earth.

The crew will use ultrasound to study decompression sickness, for example, and will research spaceflight associated neuro-ocular syndrome: a disease unique to humans who fly in space that can have severe debilitating effects. Upon landing, astronauts will undergo tests to study anemia—an unavoidable effect of traveling to space—and other conditions that might impact humans on Earth.

The scientific aims of the Polaris Program differ from the commercial spaceflight ventures offered by companies such as Blue Origin and Virgin Galactic, which could be classified more aptly as space tourism operations.

Tickets for those companies’ orbital and suborbital offerings, some of which involve research, can range from the hundreds of thousands of dollars to the millions. Isaacman and SpaceX’s Inspiration4, meanwhile, raised a quarter of a billion dollars for cancer research.

Isaacman has been particularly outspoken when it comes to accessibility in spaceflight. And by taking on much of the risk himself, the billionaire businessman has lessened the pressure on SpaceX. Isaacman’s funding of Polaris Dawn has allowed the company to focus on developing the spacesuits and other technology necessary to ensure the mission runs smoothly.

Polaris Dawn also represents a critical juncture for SpaceX’s Starship, the lynchpin of the company’s planned human spaceflight offerings. The largest rocket ever built is not quite ready to fly humans. But when it is, the third Polaris mission is expected to be its maiden voyage.

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Boeing’s CST-100 Starliner, a semireusable vessel to the ISS that has been marred by nearly a decade of delays, will finally make its first crewed flight test on Monday, barring any further hiccups. Boeing on Friday confirmed that NASA gave Starliner the “go to proceed.”

If the mission—intended to be Starliner’s final test flight—is successful, NASA will work to certify the spacecraft for routine, six-month crew rotation missions to the space station, beginning with Starliner-1, scheduled for 2025. Starliner’s crew capsule is designed to be reusable over 10 missions.

Commercial Crew is one of the linchpins of U.S. space exploration efforts. The program—a public-private partnership between NASA and companies such as Boeing, SpaceX, and Blue Origin—transports and swaps out the astronaut crews responsible for critical research on the orbital laboratory.

Used by astronauts and private companies from around the world, the space station is the only facility that allows researchers to investigate the effects of long duration spaceflight as NASA gears up for future missions to the moon, Mars, and beyond.

Since crew rotation missions began in 2020, all eight missions—including Crew-8, which is still in progress—have been facilitated by SpaceX’s Crew Dragon. The missions have also used the company’s Falcon 9 launch vehicle.

Boeing—which since 2014 has battled SpaceX for supremacy in the commercial crew program—has yet to launch a crewed flight of its Starliner, which NASA views as a redundant but important alternative to Crew Dragon. But the manufacturer on Monday has a chance to throw its hat in the ring.

“As the final flight test for Starliner, NASA’s Boeing Crew Flight Test will validate the transportation system, including the launch pad, rocket, spacecraft, in-orbit operational capabilities, and return to Earth with astronauts aboard,” NASA said in a mission profile on its website.

A successful crewed flight test would represent the final barrier to the start of Boeing’s commercial contract with NASA, under which the partners are obligated to complete six crew rotation missions. These would represent the manufacturer’s first commercial human spaceflight missions. SpaceX, so far, has flown astronauts to the space station 11 times.

A Decade of Delays

Commercial Crew is NASA’s effort to transport astronauts to the ISS from American soil, using U.S.-built rockets and spacecraft. By involving private companies such as Boeing, a rarity for the agency in years past, the idea was to reduce costs and complexity while keeping missions safe and on schedule.

Boeing unveiled the concept for the CST-100 Starliner—with CST standing for Crew Space Transportation and 100 denoting the Kármán Line, a boundary 100 kilometers above the Earth informally considered to be the edge of space—in 2010. The manufacturer claimed the spacecraft could be operational within five years.

That prediction did not come to fruition. By 2014, NASA had narrowed down its search for a reusable Commercial Crew capsule to two candidates: Starliner and SpaceX’s Crew Dragon.

Each company was awarded billions of dollars to build and certify an aircraft by 2017, the year they were expected to be ready for a first crewed flight test. Boeing’s $4.2 billion contract includes six service missions plus uncrewed and crewed test flights to the space station.

Neither company met its deadline. But Crew Dragon made its first flight with astronauts in 2020. The same can not be said for the Starliner program, which for nearly a decade has been bogged down by delays.

The first uncrewed Starliner Orbital Test Flight Mission, scheduled for 2017, was delayed three times to 2019. Half an hour into that flight, an anomaly forced NASA to abort a planned docking with the space station. Though the mission to the orbital laboratory was scrapped, the spacecraft was safely recovered.

A second uncrewed orbital test flight, OFT-2, was also delayed more than a year due to valve problems late in the initial countdown. It eventually launched in 2022, reaching the ISS for the first time and meeting all mission objectives.

The prelude to Starliner’s first crewed test flight sounds like a familiar tune. The mission was pushed back several times in 2023, culminating in an indefinite delay caused by a pair of issues discovered just weeks before a planned launch in July.

All told, the program has overrun planned costs by $1.5 billion. According to a NASA Office of the Inspector General report, the space agency committed to additional flights and payments not specified in its original contract, in a bid to keep Boeing as a contractor.

The delays to Starliner have forced NASA to put all of its eggs in SpaceX’s basket, jeopardizing Commercial Crew missions should Crew Dragon—which so far has proven reliable—experience issues. But with the agency giving its all clear last week, the long-awaited rocket spacecraft appears set to finally make its debut.

The Mission

Starliner was designed and built by Boeing with the help of more than 425 suppliers. Early missions, including next week’s planned flight, will be launched by United Launch Alliance’s Atlas V launch vehicle. But the spacecraft is billed as “launch vehicle agnostic,” compatible with vehicles in the medium-lift launch class.

Starliner’s unique weldless structure was devised with reusability in mind. Its service modules are expendable, but its crew module can be reused up to 10 times, according to Boeing. The crew module can fit seven crewmembers, but NASA missions will include four or five astronauts.

Combined, the crew and service modules have 40 reaction control system thrusters, which aid in control and steering. While the vehicle is designed to be autonomous, Boeing has trained the crew to be able to take over.

The service module has an additional 20 orbital maneuvering and attitude control thrusters and four launch abort engines, which, combined with a pusher abort system, provide an escape route in the case of emergency during launch or ascent. Stacked on top of Atlas V, the spacecraft stands just over 170 feet.

Commander Barry “Butch” Wilmore and Pilot Sunita “Suni” Williams will command next week’s planned mission. Both are experienced NASA astronauts with multiple spaceflights in the books. During the crewed test flight, Wilmore and Williams will be the first to launch on Starliner and Atlas V and manually control Starliner.

The astronauts’ goal will be to validate the transportation system, including the launch pad, rocket, spacecraft, and in-orbit capabilities, for future missions. 

Before, during, and after their weeklong stay on the space station, the crew will perform an array of tests designed to support the spacecraft’s certification. These include evaluations of equipment such as suits and seats from prelaunch through ascent, as well as assessments of communications, manual and automated navigation, life support systems, and thrusters while aboard the orbital lab.

Boeing has been “tasked with operating the entire mission,” including launch, in-orbit operations, landing, recovery and refurbishment. The company is also responsible for crew training, mission planning, spacecraft and launch vehicle assembly, and testing and integration.

Starliner arrived at Cape Canaveral Space Force Station in Florida on April 16, where it will launch from historic Space Launch Complex-41. To this point, the launch pad has only hosted uncrewed spacecraft. The spacecraft has already been stacked, with crew preparations well underway.

About 15 minutes into the mission, the Starliner capsule will separate from the booster. Orbital maneuvering and attitude control thrusters will kick in about 30 minutes in, performing an engine burn to align it in orbit and start the approximately daylong sojourn to the space station.

Cameras onboard the capsule will pick out the moving laboratory from among a sea of fixed stars as it approaches to within a few hundred feet over the following few hours. Once flight controllers give the all clear, Starliner will approach and dock autonomously with one of two Boeing-built docking adapters—another critical test.

NASA will provide continuous coverage leading up to the docking through the opening of the hatch. On Thursday, four crewmembers already aboard the space station will relocate a Crew Dragon capsule to a different docking port, making way for the SpaceX rival’s alternative.

After spending a few days evaluating the spacecraft and its systems, Wilmore and Williams will return to Starliner, which will slowly undock from the space station and position itself over the Pacific Ocean. The service module will slow it from orbital speeds of about 17,500 mph as the crew module detaches. It will then accelerate back to Earth into a parachute landing in the Western U.S., touching down at just 4 mph.

What It Means

Starliner’s first crewed test flight has plenty of implications for Boeing, NASA, and U.S. ambitions in space more broadly.

On the commercial side, failure could deal a blow to the aerospace giant, which is under contract for six NASA service missions following the flight. The company also has ambitions to attract other customers, such as Jeff Bezos’ Blue Origin, describing NASA as Starliner’s “anchor customer.”

The test flight comes as Boeing rival SpaceX continues to thrive. Before Boeing completes its first crewed mission to the space station, its rival has already completed 11 such missions—eight crew rotation missions and three private astronaut missions with customer Axiom Space—and is preparing to fly astronauts to the moon on NASA’s Artemis III.

In addition, Boeing plans to sell the extra fifth seat on its NASA missions to private and commercial- or government-sponsored astronauts. Any ambitions for private commercial spaceflight will depend on next week’s mission.

NASA would also suffer from another setback to Starliner. The space agency hopes for the space station to be continuously crewed as it uses the orbital laboratory to explore future missions to more distant destinations, such as the moon or Mars. At the moment, it is too reliant on SpaceX.

“Our hearts and souls are in this spacecraft, and a little part of us will be lifting off with Butch and Suni,” said Dana Hutcherson, deputy manager of NASA Commercial Crew and a 13-year veteran of the program.

NASA envisions visiting spacecraft such as Starliner being used as “safe havens” in the event of a contingency aboard the space station, such as depressurization, fire, or potential collision.

One such contingency took place in December 2022, when the Soyuz MS-22 capsule that transported NASA astronaut Frank Rubio to the space station sprung a coolant leak, stranding Rubio and two Roscosmos cosmonauts in orbit for months. Rubio’s 355 consecutive days aboard the ISS—his first stint in space—are now a NASA spaceflight record.

SpaceX has been a reliable partner for NASA, having not suffered an incident in service thus far. But the agency wants a contingency plan. For example, in Rubio’s case, NASA was prepared to get its astronaut home in an extra seat on a scheduled Crew Dragon launch. The backup spacecraft was not needed, but it could have rescued Rubio had Roscosmos not delivered a replacement Soyuz in time.

Boeing is also developing launch vehicles for planned NASA lunar landings during Artemis II and Artemis III. Starliner is further intended to transport personnel to the Orbital Reef, a new space station under development by Blue Origin in partnership with NASA.

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Some dragons aren’t animals at all. I’m talking about SpaceX’s Crew Dragon rocket, which on Sunday successfully docked with the International Space Station and introduced four astronauts to their new jobs for the next six months. The mission, which will support scientific research into human spaceflight beyond low-Earth orbit, is NASA’s seventh Commercial Crew rotation mission and the 11th orbital flight of Crew Dragon—to which FLYING awarded one of its 2021 Editors’ Choice Awards.

On Saturday morning, the Crew Dragon Endurance and Falcon 9 lift-launch vehicle lifted off from Launch Complex 39A at NASA’s Kennedy Space Center in Florida, reaching orbit shortly after. The launch was originally scheduled for Friday but was scrubbed so NASA teams could complete some last-minute analysis and paperwork.

Endurance docked autonomously with the space station’s Harmony module at 9:16 a.m. EDT Sunday morning. The crew of four then opened the hatch and joined seven astronauts already aboard the orbiting laboratory.

NASA provided a live stream of the launch and docking. Images and video can be found here.

“Crew-7 is a shining example of the power of both American ingenuity and what we can accomplish when we work together,” said NASA Administrator Bill Nelson. “Aboard station, the crew will conduct more than 200 science experiments and technology demonstrations to prepare for missions to the Moon, Mars, and beyond, all while benefiting humanity on Earth.”

Meet the Crew

Crew-7’s four-person roster includes astronauts from four different countries and three continents.

NASA astronaut Jasmin Moghbeli serves as commander, presiding over all phases of flight from launch to reentry. Crew-7 is the American’s first trip to space. Konstantin Borisov, a cosmonaut of the Russian space agency Roscosmos, is also leaving the Earth for the first time and serves as mission specialist, monitoring Endurance during the launch and entry phases.

Joining Moghbeli and Borisov is Satoshi Furukawa, a Japan Aerospace Exploration Agency (JAXA) astronaut for over two decades who spent 165 days on the space station in 2011. Moghbeli, Borisov, and Furukawa will serve as flight engineers for NASA Expedition 69 and Expedition 70, the agency’s 69th and 70th long-duration missions to the station.

Andreas Mogensen, a European Space Agency (ESA) astronaut who became the first Danish national in space after spending 10 days aboard a Soyuz craft on a 2015 mission to the space station, rounds out the group. Mogensen serves as pilot, responsible for spacecraft systems and performance aboard the station. He will serve as a flight engineer for Expedition 69 before taking over as commander of Expedition 70.

Living and working 260 miles above the Earth, the crew will conduct an array of research: collecting microbial samples from the space station’s exterior, studying human response to different spaceflight durations, investigating the physiological aspects of astronaut sleep, and hosting other experiments and technology demonstrations.

“The ISS is an incredible science and technology platform that requires people from all around the world to maintain and maximize its benefits to people on Earth,” said Ken Bowersox, associate administrator of the Space Operations Mission Directorate at NASA Headquarters in Washington, D.C. “It’s great seeing Crew-7 launch with four crew members representing four countries who will live and work on humanity’s home in space as we continue the nearly 23 years of a continuous human presence aboard the microgravity laboratory.”

The multinational Crew-7 group on Sunday joined the crew of Expedition 69, which includes NASA astronauts Stephen Bowen, Woody Hoburg, and Frank Rubio, UAE astronaut Sultan Alneyadi, and Roscosmos cosmonauts Sergey Prokopyev, Dmitri Petelin, and Andrey Fedyaev. That means five countries are currently represented on the station.

Already, NASA has announced astronaut assignments for the Crew-8 mission in early 2024, which will join the Expedition 70 and 71 crews to perform more operational and research activities.

NASA’s Commercial Crew program is expected to extend well beyond then. Its goal is to develop and enhance U.S. human spaceflight systems to allow safe, reliable, and cost-effective access to and from the space station (and its potential successors). The program has been active since 2010, and SpaceX was enlisted as a partner in 2014 and will continue to support rotational missions.

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