Boeing’s Crew Capsule Faces Setbacks; Next Flight May Be Uncrewed as Engineers Fix Helium Leaks, Propulsion Issues.
🔧 Starliner Grounded After Troubled 2024 Crewed Test Flight
NASA has officially grounded Boeing’s CST-100 Starliner spacecraft until at least 2026 following critical failures during its 2024 crewed test mission. The spacecraft encountered multiple helium pressurization leaks and thruster malfunctions, forcing NASA to cut the mission short and return the capsule without its crew.
NASA stated that the Starliner’s next mission may be uncrewed, depending on the progress of engineering fixes and validation tests.
🚨 What Went Wrong During the Test Flight?
The crewed test flight in June 2024 experienced several issues:
- Five out of 28 thrusters failed during the spacecraft’s approach to the International Space Station (ISS)
- Multiple helium leaks were found in the pressurization system
- The issues were traced back to thermal seal failures and overheating in the thruster compartments, known as “doghouses”
To ensure astronaut safety, NASA chose to keep the crew aboard the ISS and return the capsule to Earth empty.
🔬 Ground Testing & Engineering Fixes Underway
NASA and Boeing engineers are now conducting intensive ground testing at White Sands Test Facility:
- Thrusters are being fired in various sequences to refine thermal models
- New insulation barriers and thermal shunts have been added to prevent overheating
- Engineers are validating each subsystem before approving another flight
đź’° Budget Overruns & Delays
The Starliner program has now exceeded its original $4.2 billion budget by $2 billion, largely due to repeated delays and redesigns. Meanwhile:
- SpaceX’s Crew Dragon has completed 11 successful crewed missions to the ISS
- SpaceX’s contract with NASA has expanded to nearly $5 billion due to Starliner’s delays
Despite the challenges, NASA still considers Boeing Starliner vital as a backup to Crew Dragon for maintaining ISS crew rotations.
🛸 What’s Next for Starliner?
- NASA may require one more uncrewed flight before astronauts fly again on Starliner
- Crewed missions are unlikely to resume before late 2025 or early 2026
- Full certification is pending successful fixes and test results
Summary
Boeing’s Starliner remains grounded after a troubled test flight in 2024, with key systems failing mid-mission. While engineers work to resolve helium and thruster problems, the spacecraft’s future flights—including one potentially uncrewed—are tentatively set for 2026. NASA continues to support Starliner as an essential part of its Commercial Crew Program.
