posted 04-03-2019 10:27 AM               

NASA and Boeing Extend Starliner Crew Flight Test Duration to Space Station

NASA and Boeing have agreed to extend the duration of the company's first crewed flight test to the International Space Station after completing an in-depth technical assessment of the CST-100 Starliner systems. NASA found the long-duration flight to be technically feasible and in the best interest of the agency's needs to ensure continued access and better utilization of the orbiting laboratory.

The extended duration test flight offers NASA the opportunity to complete additional microgravity research, maintenance, and other activities while the company's Starliner is docked to station. The mission duration will be determined at a later date.

"NASA's assessment of extending the mission was found to be technically achievable without compromising the safety of the crew," said Phil McAlister, director of the commercial spaceflight division at NASA Headquarters. "Commercial crew flight tests, along with the additional Soyuz opportunities, help us transition with greater flexibility to our next-generation commercial systems under the Commercial Crew Program."

The Crew Flight Test is now targeted for late 2019, to be confirmed closer to that timeframe.

Above: Boeing's Starliner prepares for acoustic testing at Boeing's spacecraft test facilities in El Segundo, California. This vehicle, known as Spacecraft 2, will fly Starliner's Crew Flight Test after it returns to Florida from environmental testing. (Boeing)

Boeing's Crew Flight Test spacecraft recently completed its Environmental Qualification Test campaign at the company's Space Environment Test Facilities in El Segundo, California. The Crew Flight Test vehicle underwent rounds of acoustics vibration, thermal vacuum and electromagnetic interference and electromagnetic contamination testing. These tests are designed to simulate the harsh environments of launch, ascent and orbit and also prove that the electronics systems will operate in space and not interfere with other satellites or the station.

NASA astronauts Nicole Mann and Mike Fincke and Boeing's Chris Ferguson are continuing preparations for the Crew Flight Test at Johnson Space Center in Houston. They are training on Starliner's systems, including nominal and unlikely scenarios, such as water rescue training. They are also well into space station training, and are now focusing on becoming a longer duration crew. Mann and Fincke are training for upcoming spacewalks, and Ferguson is training to support them from inside the station.

posted 04-12-2019 02:02 PM               

Ready for Orbit! Starliner Passes Environmental Qualification Testing

"Test like you fly" is a mantra Boeing's CST-100 Starliner team takes to heart, proven by the success of a recent environmental test campaign at Boeing's Space Environment Test Facility in El Segundo, Calif. During testing, the first Starliner that will carry people to space was subjected to similar environmental conditions it will see on launch, ascent and orbit.

"Environmental testing is one of the most challenging campaigns of any spaceflight development program, and we succeeded in under 100 days," said John Mulholland, Vice President and Program Manager, Boeing's Commercial Crew Program. "Thorough ground testing is a critical part of our strategy to ensure the shortest possible time between flight tests and long-duration missions for our NASA customer."

In Boeing's acoustic chamber, test teams subjected Starliner to intense sound waves that simulated liftoff and ascent. In the large thermal-vacuum chamber, the spacecraft experienced extreme temperature swings, from freezing cold to heat from solar radiation in a vacuum simulating the space environment. Finally, teams tested the spacecraft's systems for potential electromagnetic interferences in a highly specialized, noise-free anechoic chamber.

The complex series of tests was needed to qualify Starliner for repeated missions to and from the International Space Station, with crew safety always the top priority.

In addition to environmental qualification testing, another version of Starliner specifically created for structural testing was put through hundreds of unique conditions, which yielded several billion points of data needed to validate Starliner's structural design. Read more about that testing here.

"We put the spacecraft through a gauntlet of tests to prove it's ready," said Boeing Test & Evaluation's Space Environmental Test Leader Brad Mejia. "Everything we needed to conduct the testing, including a team of experts who are used to testing for space, are right here in southern California."

Having successfully completed environmental qualification testing, the spacecraft was carefully packaged and shipped via semi-truck back to Florida, where it will first leave the planet. There, teams will continue readying the spacecraft for that highly-anticipated first crewed launch into space.

posted 05-23-2019 08:27 PM               

Atlas V departs factory for historic mission

The first Atlas V rocket to launch astronauts into space emerged from the United Launch Alliance factory today, rolling into a giant cargo ship for transport to Cape Canaveral.

Above: The Atlas V booster and Centaur stages leave the Decatur factory on May 23, 2019 for the CFT launch.

ULA built the Atlas V at the sprawling 1.6-million-square-foot manufacturing facility in Decatur, Alabama, taking raw materials and turning them into a rocket to launch the first crew of Boeing's CST-100 Starliner spacecraft.

After speeches celebrating the milestone by Alabama elected officials and ULA and Boeing dignitaries in attendance, ULA workers moved the Atlas V booster stage and Centaur upper stage down the road for loading into the Mariner vessel docked nearby.

The 312-foot-long ship is purpose-built to navigate both shallow waters of rivers and ocean travel to reach ULA's launch sites. It has been making the trek from Decatur to Cape Canaveral since 2001.

Above: The Atlas first stage for CFT travels down the road the Decatur dock.

This rocket, known as AV-082, will launch Starliner on the Crew Flight Test (CFT) to the International Space Station part of NASA's Commercial Crew Program. CFT will follow the maiden voyage of Starliner, the uncrewed Orbital Flight Test (OFT) targeted for August.

Aboard will be Boeing astronaut Chris Ferguson, a three-time space shuttle astronaut and commander of space shuttle Atlantis on the final shuttle mission; NASA astronaut Mike Fincke, a veteran of three spaceflights, including two long-duration stays on the International Space Station, and NASA astronaut Nicole Mann, a spaceflight rookie making her first trip into space.

Once at Cape Canaveral Air Force Station in Florida, the Atlas V will begin integrated operations and processing for the CFT launch.

posted 10-07-2020 10:06 AM               

Astronaut Chris Ferguson withdraws from Boeing Starliner test flight

Boeing's first commercial astronaut has stepped down from commanding the first crewed test flight of the company's new spacecraft, citing family commitments.

Chris Ferguson has been replaced by NASA astronaut Barry "Butch" Wilmore aboard the CST-100 Starliner Crewed Flight Test (CFT), which is targeted to lift off to the International Space Station in 2021. The change comes two years after Ferguson was assigned to fly on the mission with NASA astronauts Mike Fincke and Nicole Mann.

"Next year is very important for my family. I have made several commitments, which I simply cannot risk missing," said Ferguson in a video statement on Wednesday (Oct. 7). "I'm not going anywhere, I'm just not going to space next year."

posted 10-06-2021 10:28 AM               

Mann reassigned from Starliner Crew Flight Test

NASA has reassigned astronaut Nicole Mann to the agency's SpaceX Crew-5 mission to the International Space Station as part of the Commercial Crew Program.

Mann was previously assigned to Boeing's Crew Flight Test. NASA decided it was important to make this reassignment to allow Boeing time to complete the development of Starliner while continuing plans for astronauts (like Mann) to gain spaceflight experience for the future needs of the agency's missions.

NASA astronauts Butch Wilmore and Mike Fincke will continue to provide experience for Boeing as the agency prepares for NASA's Boeing Crew Flight Test. Additional Boeing flight assignments will be made in the future.

Mann is a California native and a colonel in the Marine Corps. She earned a Bachelor of Science in mechanical engineering from the United States Naval Academy and a Master of Science in mechanical engineering with a specialty in fluid mechanics from Stanford University. She is an F/A-18 test pilot with more than 2,500 flight hours in more than 25 aircraft. NASA selected Mann as an astronaut in 2013. This will be her first trip to space.

"It has been the opportunity of a lifetime to train on a brand-new spacecraft, the Boeing Starliner, and it has been fantastic to work with the Boeing team," Mann said. "I am thrilled to have the opportunity to train on another new spacecraft – the SpaceX Crew Dragon – and appreciate the teams at NASA who have made that possible. I am ready to fly and serve on the International Space Station."

posted 06-16-2022 02:00 PM               

NASA assigns two astronauts to Boeing's Starliner crew flight test

NASA has selected the first crew to fly on board Boeing's new commercial spacecraft.

Barry "Butch" Wilmore and Suni Williams will fly on the Crew Flight Test (CFT) of the CST-100 Starliner capsule, launching as soon as perhaps later this year. The two veteran astronauts will spend about two weeks in Earth orbit, with most of the mission spent at the International Space Station.

posted 11-03-2022 10:18 AM               

NASA, Boeing adjust Starliner Crew Flight Test launch date

The Crew Flight Test (CFT) of Boeing's CST-100 Starliner is now targeted to launch in April 2023, a window Boeing and NASA agree is the optimal timeframe for the International Space Station visiting vehicle schedule.

"We understand our customer must consider the needs of the International Space Station in scheduling the certification flight of a second U.S. commercial crew transportation system," said Mark Nappi, vice president and program manager for the Starliner program. "We are working to have the CFT vehicle ready to fly ahead of the new launch date."

The refurbishment of a previously flown crew module and production of a new service module for CFT are continuing at Boeing's Commercial Crew and Cargo Processing Facility in Florida. Once both modules are complete, they'll be mated and tested for flight.

The Starliner team recently completed a successful Crew Validation Test (CVT) with NASA astronauts Butch Wilmore, Suni Williams and Mike Fincke. CVT is a critical milestone conducted near completion of the crew module and is a measure of confidence for the astronauts as they progress toward launch.

Boeing and NASA are working together to achieve flight readiness. In-flight anomalies from Starliner's Orbital Flight Test-2 (OFT-2) are on a path to close in the coming weeks, following thorough data reviews, fault tree analyses, and agreed-to mitigation plans.

"Starliner's two uncrewed orbital flight tests provided invaluable information about our spacecraft," Nappi said. "Additional learnings are expected as Starliner transitions from a fully autonomous flight without crew to flights with crew. With the help of experienced NASA test pilots, Wilmore and Williams, we are closer to our goal of flying a safe and capable spacecraft."

posted 12-15-2022 01:03 PM               

Teams Train for Starliner's First Crewed Flight

NASA and Boeing teams continue to conduct training and testing ahead of the Boeing Crew Flight Test (CFT), scheduled to launch in April 2023 to the International Space Station for the agency's Commercial Crew Program.

For the crewed flight test, Boeing's CST-100 Starliner spacecraft will launch aboard a United Launch Alliance Atlas V rocket from Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida, returning approximately eight days later in White Sands, New Mexico.

Most recently, the CFT Super Suited Week took place at NASA's Johnson Space Center in Houston in late October through early November. During the training, NASA astronauts Barry "Butch" Wilmore and Suni Williams, CFT commander and pilot, respectively, and Mike Fincke, CFT backup spacecraft test pilot, donned their spacesuits while participating in various simulations, good day and bad day scenarios, and spacecraft ingress and egress. The event also gave the crew extended time to get comfortable wearing their suits.

Prior to that, the astronauts participated in a crew validation test in October to evaluate and fine tune operations. These tests provide astronauts with hands-on training while giving the launch pad crew further experience with crucial tasks. In addition, teams can address issues encountered during previous checks and identify items that still need to be resolved prior to launch.

During the exercise, the astronauts suited up and tested the pressurized crew module to assess seat fit, suit functionality, cabin temperature, audio, and day of launch operations. The teams cycled through different environmental control configurations and flow rates, including oxygen and emergency gas, so the crew will be accustomed to a variety of scenarios on orbit. The astronauts also familiarized themselves with camera, tablet, and wireless application set-up. Communication checks went well between the Mission Control Center and the crew in the spacecraft.

Overall, the training activities gave the astronauts and support teams confidence in operations and built their knowledge base for subsequent flight preparation activities.

"Preparing for this flight doesn't feel like traditional training that Suni and I went through for missions on the space shuttle or Soyuz," Wilmore said. "We're thoroughly embedded in all aspects of developing a brand-new spacecraft, making this more akin to an experimental process. The entire team is learning how to plan, train, and fly Starliner into space."

posted 01-24-2023 10:00 AM               

Starliner Spacecraft Readied for Crew Flight Test

The Starliner spacecraft for the Crew Flight Test (CFT) is now complete, following the mating of its crew and service modules.

Above: The Starliner team works to finalize the mate of the crew module and new service module for the Crew Flight Test that will take NASA astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams to and from the International Space Station. (Boeing/John Grant)

Boeing's CST-100 Starliner team completed the production milestone on Thursday, Jan. 19, in advance of the planned April launch with NASA astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams to the International Space Station.

During the operation, a crane lifted the reusable crew module atop the brand-new service module in the Commercial Crew and Cargo Processing Facility at NASA's Kennedy Space Center to become a fully operational spacecraft.

"Every member of our team is invested in giving Butch and Suni a great ride to the International Space Station," said Mark Nappi, vice president and program manager for the Starliner program. "We're building off the successes and lessons learned from Orbital Flight Test-2, and all of the pieces for CFT are coming together."

With a completed spacecraft, teams will continue outfitting the crew module's interior, conducting integrated vehicle testing and performing final spacecraft checkouts. The spacecraft will then undergo weight and center of gravity testing prior to rolling out of the Starliner factory en route to its United Launch Alliance Atlas V launch complex.

CFT is targeted to launch in April 2023, in accordance with the International Space Station visiting vehicle schedule.

posted 02-24-2023 11:15 AM               

Starliner Crew Performs Cabin Operations, Checks Out Tools

NASA astronauts assigned to the Starliner's upcoming Crew Flight Test (CFT) completed the first part of a two-part Crew Equipment Interface Test (CEIT) this week. CEIT is a critical milestone for NASA, Boeing and the International Space Station program, typically conducted about two months prior to launch. It gives astronauts the opportunity for hands-on training with the actual tools, equipment and hardware they'll use on orbit.

Above: NASA astronauts Barry "Butch" Wilmore, Sunita "Suni" Williams and Mike Fincke review some cargo items for the Crew Flight Test with Deanna "Dee" Dobson, Boeing Starliner's Crew and Cargo Accommodations subsystem engineer. (Boeing/John Proferes)

For Starliner's first flight with crew, that included various familiarization operations inside the spacecraft for NASA astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams, who are CFT commander and pilot, respectively, and backup test pilot NASA astronaut Mike Fincke.

Over the course of two days, the CFT crew worked closely with the Starliner team to perform in-cabin checkouts. They made adjustments to the spacecraft seats; inspected spacecraft interfaces; removed and replaced cargo shelf pins; and conducted floor panel and side hatch operations. They also had a chance to look over cargo and get hands-on experience with spacecraft tools prior to packing and stowing.

The second part of CEIT is scheduled to occur in early March, and will include the astronauts maneuvering about the cabin with cargo installed in the spacecraft.

Above: NASA astronauts Barry "Butch" Wilmore and Sunita "Suni" Williams test their spacesuit gloves on an Instrument and Control Panel as part of Crew Equipment Interface Test (CEIT) on February 22, 2023 at Boeing's Commercial Crew and Cargo Processing Facility. (Boeing/Deborah Circelli)

Above: NASA astronauts Sunita "Suni" Williams and Mike Fincke in the Crew Flight Test (CFT) vehicle as part of the Crew Equipment Interface Test (CEIT) on February 21, 2023 at Boeing's Commercial Crew and Cargo Processing Facility. (Boeing/John Proferes)

posted 03-29-2023 01:49 PM               

Starliner's Crew Flight Test now targeted for July

NASA and Boeing are now targeting July for the Starliner's Crew Flight Test (CFT) as the teams work together to close out verification items and the agency manages a busy flight schedule to and from the International Space Station (ISS) during the next few months.

Representatives from NASA's Commercial Crew and ISS programs announced the update at a media telecon Wednesday (March 29). While the Starliner spacecraft build is complete, additional time is needed to close out verification and validation work prior to the system's first flight with crew on board.

"We are very proud of the work the team has done," said Mark Nappi, vice president and Starliner program manager. "We understand the significance of this mission for both us and NASA. We will launch when we are ready and that includes at a time when the International Space Station can accept our vehicle."

Meanwhile, the spacecraft's integrated vehicle testing is going well. The crew module's interior is in its flight configuration and cargo is loaded with the exception of late-stow items. Last week, NASA astronauts and CFT Commander Barry "Butch" Wilmore and Pilot Sunita "Suni" Williams, and backup pilot Mike Fincke, finished the second part of the Crew Equipment Interface Testing milestone. They maneuvered around the spacecraft getting hands-on experience with the tools and equipment they will use during the flight test.

Wilmore, Williams and Fincke will also conduct several simulations focused on the spacecraft's backup manual flight mode for added redundancy in the event of an emergency. Fueling the spacecraft and loading updated software flight parameters ensuring alignment with the ISS will be conducted closer to launch.

posted 05-26-2023 03:48 PM               

NASA, Boeing Provide Update on Starliner Flight Test Readiness

NASA and Boeing completed a joint Crew Flight Test checkpoint review May 25 ahead of the first flight of Starliner with astronauts to the International Space Station. During the checkpoint, mission teams reviewed open work ahead of launch planned no earlier than July 21, including emerging issues that need a path to closure prior to a decision to fuel the spacecraft in June.

"We are taking a methodical approach to the first crewed flight of Starliner incorporating all of the lessons learned from the various in-depth testing campaigns, including Starliner's flight tests and the agency's verification efforts," said Steve Stich, manager of NASA's Commercial Crew Program. "All Orbital Flight Test-2 anomalies are closed. In addition to the closeout of ongoing work, the team remains vigilant on tracking new technical issues as we complete certification for crewed flight."

As part of the ongoing effort, 95% of the Crew Flight Test certification products are complete. This includes approval of Starliner's crew module batteries, based on additional testing and analysis, along with post-certification flight mitigations and a proposed battery upgrade for future missions. Teams are conducting final spacecraft closeouts and preparing for upcoming hardware milestones, including spacecraft fueling, spacecraft rollout to the launch site, and integration with the United Launch Alliance Atlas V rocket.

While the team continues to work the remaining certification products, they also are working resolution paths on the following items:

Teams will remove and replace a by-pass valve on the active thermal control system, which is located on the Starliner service module and is used to flow coolant into the system to cool the onboard avionics. The Starliner team is replacing the valve that was restricting flow to one of two redundant loops, and running a diagnostic to confirm the suspected issue with the malfunctioning hardware. This work is expected to take about a week with no overall impact to the launch schedule at this time.

Engineers also are working to evaluate any elevated risk from a specific type of tape used on the spacecraft to protect wires from chaffing. Although the tape is commonly used in spaceflight, the adhesive properties of the tape could present a flammability risk under certain conditions. NASA and Boeing are evaluating this material and the system's overall wiring protection to confirm it is acceptable for crewed flight. Those efforts are ongoing and are expected to complete before Boeing begins fueling operations on the spacecraft.

NASA and Boeing also are working to reassess Starliner's parachute system margins based on new data reviews as part of the ongoing design certification process. Engineers are reviewing the overall efficiency of certain joints within the parachute system to confirm they meet all required factors of safety for crewed flight.

"Crew safety remains the highest priority for NASA and its industry providers, and emerging issues are not uncommon in human spaceflight especially during development," said Stich. "If you look back two months ago at the work we had ahead of us, it's almost all complete. The combined team is resilient and resolute in their goal of flying crew on Starliner as soon as it is safe to do so. If a schedule adjustment needs to be made in the future, then we will certainly do that as we have done before. We will only fly when we are ready."

Starliner spacecraft fueling is expected to begin as early as mid-June, and there is some operational flexibility in that timeline that can be used if needed. Teams will continue to monitor the forward work and determine whether an adjustment in the current launch date is needed. An update on the team's progress will be provided in the coming weeks.

posted 06-01-2023 07:13 PM               

Boeing Statement on Starliner CFT Status

Boeing's priority for Starliner's Crew Flight Test is the safe launch, docking and return of Butch Wilmore and Suni Williams. For that reason, we have recommended to NASA that we reevaluate our launch window to allow for closing out the remaining technical and certification items.

We were notified by the parachute supplier of an issue, identified through testing, that reduced our safety margin. Our engineering team provided additional analysis and given that, we determined the safest course of action was to stand down for the July launch opportunity.

We are now determining when we will be ready to launch, but anticipate additional parachute testing. We are committed to the Starliner program and are working closely with NASA to identify a new launch date.

posted 08-09-2023 12:52 PM               

NASA, Boeing Provide Update on Starliner Crew Flight Test

NASA and Boeing teams continue to make progress in preparing for Starliner's first crewed flight to and from the International Space Station.

In a media teleconference Aug. 7, leaders from NASA and Boeing discussed the path forward for the spacecraft, including work to address technical concerns with the vehicle's parachutes and the use of flammable tape that was identified during the agency's certification process to ensure the system meets crew safety requirements.

The Starliner team expects to have the Crew Flight Test spacecraft ready in March 2024. A specific target launch date will be set closer to spacecraft readiness, and with consideration of the International Space Station, United Launch Alliance, and Eastern Range availability.

posted 10-23-2023 01:46 PM               

Progress Continues Toward Crew Flight Test

NASA and Boeing are working to complete the agency's verification and validation activities ahead of Starliner's first flight with astronauts to the International Space Station. While Boeing is targeting March to have the spacecraft ready for flight, teams decided during a launch manifest evaluation that a launch in April will better accommodate upcoming crew rotations and cargo resupply missions this spring.

Above: Inside Boeing's Commercial Crew and Cargo Processing Facility at NASA's Kennedy Space Center in Florida on Jan. 19, 2023, the Starliner team works to finalize the mate of the crew module and new service module for NASA's Boeing Crew Flight Test that will take NASA astronauts Butch Wilmore and Suni Williams to and from the International Space Station. (Boeing/John Grant)

Once the spacecraft meets the agency's safety requirements, NASA's Boeing Starliner Crew Flight Test (CFT) will see astronauts Butch Wilmore and Suni Williams perform the first crewed mission of the spacecraft designed to take astronauts to and from the orbital laboratory.

Ahead of CFT, Boeing has completed P213 tape removal in the upper dome of the Starliner crew compartment and work is underway to remove or remediate the tape in the lower dome of the spacecraft. These hardware remediation efforts inside the Starliner production facility at NASA Kennedy are expected to be completed during the next several weeks. After the P213 tape remediation efforts conclude, engineers will conduct final assessments to ensure acceptable risk of any remaining tape.

A set of parachutes is on track to be delivered and installed on the CFT spacecraft by the end of this year to support the current target launch date. Separately, the team also is planning a drop test of Starliner's updated drogue and main parachutes. The parachutes will incorporate a planned strengthening of main canopy suspension lines and the recent design of the drogue and main parachute soft-link joints, which will increase the safety factor for the system. The drop test is planned for early 2024 based on the current parachute delivery schedule.

Boeing and NASA also are planning modifications to the active thermal control system valves to improve long-term functionality following a radiator bypass valve issue discovered during ground operations earlier this year. As discussed during a Starliner media teleconference in June, teams have modified the spacecraft hardware and identified forward work to prevent a similar issue in the future. Options include a system purge to prevent stiction, component upgrades and operational mitigations.

Additionally, about 98% of the certification products required for the flight test are complete, and NASA and Boeing anticipate closure on remaining CFT certification products early next year. Meanwhile, NASA and Boeing have made significant progress on requirement closures related to manual crew control of the spacecraft and abort system analysis.

The latest version of Starliner's CFT flight software completed qualification testing and is undergoing standard hardware and software integration testing inside Boeing's Avionics and Software Integration Lab. Starliner's crew and service modules remain mated and await continuation of standard preflight processing.

The United Launch Alliance Atlas V rocket also is in Florida at Cape Canaveral Space Force Station awaiting integration with the spacecraft.

The NASA astronauts who will fly aboard CFT continue to train for their roughly eight-day mission to the orbiting laboratory, which includes working with operations and mission support teams to participate in various simulations across all phases of flight.

posted 01-12-2024 06:39 PM               

Starliner Parachute System Upgrade Tested Before Crewed Flight

A modified parachute system for Boeing's Starliner spacecraft for NASA's Commercial Crew Program was tested over the Arizona desert on Jan. 9. Parachute deployment and a soft landing of the test article were visually confirmed. Preliminary data analysis of this two-parachute test suggest the primary test objectives were met. Engineering teams will continue to review the results, inspect the test parachutes, and work to complete system certification in the weeks ahead.

Above: A NASA C-130 cargo aircraft releases a dart-shaped test vehicle above the U.S. Army's Yuma Proving Ground on Jan. 9 to begin the testing sequence for a Boeing Starliner parachute system. (U.S. Army Yuma Proving Ground)

In the meantime, NASA and Boeing are proceeding with preparations for Starliner to carry astronauts for the first time to the International Space Station during the Crew Flight Test, currently slated to launch no earlier than mid-April on a mission lasting about 10 days.

The drop test, which used a Starliner parachute system attached to a dart-shaped sled the same weight as a Starliner, was performed to confirm the functioning of a redesigned and strengthened soft link joint that is part of the network of lines connecting the parachutes to the spacecraft. The test also validated a change to strengthen one textile joint in the parachute, increasing overall parachute robustness. As with other capsules, Starliner relies on parachutes to land safely when it returns to Earth.

Above: A pair of parachutes lower the dart-shaped test vehicle to the ground to conclude the drop test for a modified parachute for the Starliner spacecraft. (U.S. Army Yuma Proving Ground)

A C-130 cargo aircraft from NASA's Wallops Flight Facility in Virgina, carried the test article and parachutes high above the U.S. Army's Yuma Proving Ground in Arizona before releasing them. Engineering teams, CFT astronauts Butch Wilmore, Suni Williams and Starliner-1 astronaut Mike Fincke watched from the drop zone below. The Starliner main parachutes were lifted from the test article using flight-like pilot parachutes before inflating fully to slow the test dart to the same soft-landing velocity experienced by the Starliner spacecraft in flight.

Starliner completed two uncrewed flight tests including Orbital Flight Test-2, which docked to the space station on May 21, 2022.

posted 01-24-2024 04:55 PM               

NASA, Boeing Move into Next Phases of Flight Test Prep

NASA and Boeing teams are preparing for a flight test no earlier than mid-April in which the Starliner spacecraft will carry two NASA astronauts to the International Space Station.

Teams have made significant progress in resolving technical issues identified during the agency's flight certification process. Following a successful drop test earlier this month in which recent modifications to Starliner's parachute system were validated, NASA and Boeing are working to perform final analysis of the test data and complete overall system certification ahead of Starliner's first crewed flight. This standard NASA process is designed to independently verify Starliner's parachute system meets crew safety requirements and is expected to continue over the next six to eight weeks.

Meanwhile, Boeing completed removal of P213 tape that may have posed a flammability risk in certain environmental conditions. Boeing removed more than 17 pounds, or roughly 4,300 feet, of the material from the Starliner crew module. For areas in which removal of the tape carried an increased risk to Starliner hardware, Boeing applied tested remediation techniques such as overwrapping the P213 tape with another non-flammable, chafe-resistant tape, and installing fire breaks on wire harnesses. The agency worked to clarify the properties and safe usage guidance relative to P213 tape in the NASA Materials Usage Agreements database to prevent a similar misapplication from occurring across industry in the future.

Additionally, major integrated flight operations exercises are underway. Mission support teams recently completed a two-day undock to landing mission dress rehearsal with recovery personnel on the ground at White Sands Missile Range in New Mexico. Teams simulated Crew Flight Test procedures and spacecraft sequences starting with pre-undock powerup and continuing through undock, entry, landing, and crew recovery. The exercise provided an additional training opportunity for NASA and Boeing to practice Starliner's return to Earth in a high-fidelity environment before the flight.

Teams from ULA (United Launch Alliance) are preparing the Atlas V rocket hardware for processing and spacecraft integration. Boeing is targeting completion of Starliner assembly at the end of January. The upgraded parachutes were delivered and installed on the spacecraft, along with Starliner's forward heat shield and ascent cover. Prior to fueling operations, following final installation of thermal protection system blankets and internal closeout work, Boeing will begin flowing a nitrogen purge into the Starliner's service module to ensure ambient moisture does not permeate into the propulsion isolation or active thermal control system valves. In the weeks ahead, NASA and Boeing will work to identify any remaining work before loading Starliner propellant.

The next couple of months teams will:

• work to complete overall Crew Flight Test certification;
  
• put the finishing touches on the Starliner spacecraft, which is already joined to its service module;
  
• run simulations of operational conditions to rehearse every phase of the mission with the crew, flight controllers, and ground operations teams;
  
• fuel the spacecraft with propellants for its onboard thrusters for in-space maneuvering;
  
• stack the ULA Atlas V rocket and Starliner spacecraft before rolling them to the pad at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida;
  
• and work through detailed systems reviews, culminating with a flight readiness review in the days before launch to verify the system and teams are ready.

Starliner's Crew Flight Test will launch NASA astronauts Butch Wilmore and Suni Williams to the orbiting laboratory for a stay of one to two weeks before returning them to a landing in the southwest United States. The mission will mirror the tasks of regular crew rotation flights for Boeing's Starliner under contracts with NASA's Commercial Crew Program.

posted 03-18-2024 11:56 AM               

Fueling begins for the Starliner Crew Flight Test

Loading the spacecraft with propellant is the next milestone on the path to launch.

Spacecraft fueling has begun for the upcoming Crew Flight Test (CFT) as the Starliner team prepares to send its first crew to the International Space Station.

Above: The Starliner team recently moved the spacecraft to the Hazardous Processing Area inside the factory at the Commercial Crew and Cargo Processing Facility in Florida to prepare for fueling. (Boeing/John Grant)

The Starliner spacecraft, consisting of a reusable crew and expendable service module, was recently moved into the Hazardous Processing Area at Boeing's Commercial Crew and Cargo Processing Facility (C3PF) at Kennedy Space Center in Florida. Fueling the spacecraft will take a little more than two weeks.

Conducting the propellant loading operation is a team made up of specially trained technicians, as well as fluids, propellant and electrical test engineers. To perform the operation, technicians wear what's called a SCAPE suit. SCAPE stands for Self-Contained Atmospheric Protective Ensemble and the suit protects them from any hazardous commodities. Throughout the operation, test teammates monitor the spacecraft, including sensors and valves, as well as the environment within the C3PF.

Following fueling, final closeout activities will be performed for the spacecraft's rollout from the factory to United Launch Alliance's Vertical Integration Facility at Cape Canaveral Space Force Station. Closeout activities include removing propellant access panels, placing environmental covers over the spacecraft's thrust nozzle outlets, performing thermal protection system work, checking the spacecraft's final weight and center of gravity, and loading it onto the transport vehicle.

posted 04-05-2024 04:15 PM               

Starliner fueled for Crew Flight Test

With propellant loading complete, the Boeing spacecraft soon will be transported to the launch site.

The Boeing CST-100 Starliner spacecraft is fully fueled for the Crew Flight Test (CFT), now targeted to launch to the International Space Station on May 6.

Over the past two weeks, specially trained technicians loaded five different commodities into the spacecraft. Each commodity goes in individually and in sequential order under the careful direction of Starliner's test team.

"Samples were taken and specialized tests were conducted throughout the propellent loading process to ensure the safety of the team performing the operation and the safe operation of the spacecraft on orbit," said Mark Sorensen, Starliner CFT Crew Module lead.

Up next for the spacecraft is a final weight and center-of-gravity check. In mid-April, the spacecraft will be transported to United Launch Alliance's Vertical Integration Facility at Cape Canaveral Space Force Station in Florida and integrated to the top of the Atlas V rocket.

posted 04-15-2024 04:21 PM               

Starliner Rollout Preparations Continue

Weight and center-of-gravity operations complete

Following fueling and checkout operations, the Boeing team moved the Crew Flight Test spacecraft out of the Starliner facility's hazardous processing area to a machine that weighs and measures the center of gravity (CG) of the spacecraft. Using the high bay crane, the engineers and technicians lifted Starliner into place and secured it onto the machine.

Above: CFT Starliner spacecraft during final weight and CG. (Boeing)

Previous weigh-ins of the Crew Module and Service Module, where the weight and CG machine tilts the elements up to 30 degrees along their principle axes, were taken to get highly accurate measurements of the individual elements. Once mated, loaded with cargo and fueled, a final weight and CG measurement is taken of the completed spacecraft.

Through this method, engineers are able to validate an accurate center of gravity of the entire integrated spacecraft, which needs to be within a volume about the size of an American quarter. Accurate weight and CG measurements are critical to the nominal performance of both the entire integrated spacecraft and launch vehicle during ascent and the spacecraft during on-orbit maneuvers and reentry.

Above: Starliner on the KAMAG in the Starliner factory. (Boeing)

After the weight and CG measurements, the Boeing team used the high bay crane again to move Starliner to a staging area inside the high bay, where a transport vehicle provided by ULA known as a KAMAG, or "K-MAG," was waiting. The team then secured Starliner to the transporter, where it is now ready for the overnight trek to its launch site, Space Launch Complex-41.

posted 04-16-2024 11:16 AM               

Boeing CFT Starliner rolled out

Boeing's Starliner spacecraft, set to carry NASA astronauts Butch Wilmore and Suni Williams on the agency's Boeing Crew Flight Test to the International Space Station, rolls out of the company's Commercial Crew and Cargo Processing Facility at NASA's Kennedy Space Center in Florida on Tuesday, April 16, 2024.

The spacecraft is being transported to ULA's (United Launch Alliance) Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station to be lifted and connected to the Atlas V rocket for launch no earlier than Monday, May 6, 2024.

posted 04-16-2024 01:43 PM               

Starliner takes its place atop an Atlas V rocket

The spacecraft moves closer to launch after an early morning factory rollout.

Starliner teammates cheered as the headlights of the transporter slowly neared the corner of the Commercial Crew and Cargo Processing Facility, soon revealing the Crew Flight Test spacecraft they've worked so hard on.

Knowing NASA astronauts Butch Wilmore and Suni Williams, who were also watching with them, will be flying on board for Starliner's first crewed flight makes the milestone even more special for the team.

The Starliner rolled out from the back of the factory on a transport vehicle and left the parking lot at about 5 a.m. Eastern time. It made a slow, carefully orchestrated 10-mile (16-kilometer) trek to United Launch Alliance's Vertical Integration Facility (VIF) at Cape Canaveral Space Force Station.

The spacecraft was later hoisted and integrated on top of ULA's Atlas V rocket. Work will continue in the VIF before the May 6 launch to ensure the Atlas V and spacecraft are properly communicating with each other prior to launch.

The milestone has special meaning for launch campaign managers Richard Skinner and Amanda Ireland.

For Skinner, the rollout signifies nearing the end of a long career in human spaceflight, starting with working shuttle payloads in 1980 for McDonnell Douglas. He has also worked for ULA and the Space Launch System and was brought on to help Starliner with the orbital flight tests and then through the first crewed flight.

"Having a chance to get to meet and personally know our flight crew members, it will mean that much more when we see them leave for the pad," said Skinner, who is also the convoy coordinator overseeing the transport operation of crew to ULA's launch complex.

Ireland, who is also lead of launch operations and sits on console as the spacecraft liaison officer during launch, has been on the Starliner program for five years.

"Doing this work has been my dream job for a long time and it continues to be," Ireland said. "So seeing us launch astronauts means everything."

The two coordinated the rollout along with teams from Boeing and ULA, as well as Boeing and NASA security, and the U.S. Space Force.

A lot is involved before rollout, including making sure various antennas and GPS systems are working correctly in communicating information back and forth from the rocket to the Boeing Mission Control Center.

Now that the spacecraft is mated to the Atlas V, that work continues. Teams will go through a series of functional testing to make sure everything is connected correctly and communicating properly with the spacecraft and rocket.

Functionally this rollout was similar in nature to previous rollouts, Ireland said, including "treating the spacecraft with the greatest care and detail." Ireland said the importance of having a successful Crew Flight Test is essential in ensuring multiple providers are able to reach different low Earth orbit locations in the future while advancing human spaceflight.

Another teammate, Mackenzie Palafox, worked with Skinner and Ireland on the rollout. Palafox has been with Starliner a little over a year, primarily as a manufacturing engineer, and agreed to take on the additional responsibilities to assist the launch campaign managers.

"I am so proud to be a part of this company's legacy in human spaceflight," Palafox said. "It's really amazing to see it all coming together."

Other members of the Starliner team were also on hand to watch the spacecraft leave the factory.

They cheered and snapped photos as the spacecraft made its way from around the Commercial Crew and Cargo Processing Facility.

Carol Wingrove, an electrical technician, who has been on the Starliner program for nine years, was thrilled to see the Starliner astronauts watching the rollout and all the support they've provided the team.

"I'm excited for everyone. We've waited so long," Wingrove said. "We have astronauts on board. We made it. It took a lot of hard work from everybody, but it's worth it to get to this point."

Max Plavcan, Starliner Crew & Cargo Accommodations systems engineer, attended his first rollout. He started on Starliner as an intern in 2017 and was hired full time in 2020.

"It all feels surreal," Plavcan said.

Rob Hughes, Starliner manufacturing engineer for four years, said he's looking forward to sending crew to the space station and welcoming them home.

"This is why we all do this," Hughes said. "It makes all the hard work we've done really pay off."