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The Boeing Starliner capsule “Calypso” has now been stuck in space for 60 days, far beyond its scheduled nine-day mission. 

The mission has been extended several times while Boeing and NASA conduct testing both on Earth and in Space in an attempt to understand a myriad of ongoing thruster problems.

Starliner flew NASA astronauts Butch Wilmore and Suni Williams to the International Space Station ISS) in early June. But the mission has been plagued with serious problems.

An unprecedented situation is unfolding as Boeing and NASA grapple with ongoing thruster issues. What was supposed to be a routine crewed test flight has turned into a complex engineering challenge.

 The situation raises questions about Boeing's continued role in NASA's Commercial Crew Program and the future of private space travel.

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Starliner capsule “Calypso” Mission 

Starliner carried NASA astronauts Butch Wilmore and Suni Williams to the International Space Station (ISS) in early June. However, the mission has been beset by significant technical problems that have forced multiple extensions.

In recent testing, NASA reported that 27 of Starliner’s 28 thrusters, also known as the Reaction Control System (RCS) engines, are functioning properly. 

These engines are essential for maneuvering the spacecraft in orbit. However, the ongoing thruster issues have left NASA management facing a difficult decision: whether to bring the astronauts back on the misfiring Starliner capsule or to use SpaceX’s Crew Dragon for their return.

Thruster Troubles

The thruster problems began before the mission even launched, causing several delays. These issues resurfaced during docking at the ISS, further complicating the mission. NASA has yet to identify a definitive root cause for the thruster malfunctions, which poses a significant risk for the return flight.

"We remain confident in the Starliner spacecraft and its ability to return safely with crew," a Boeing spokesperson stated to CNBC on Friday. "We are supporting NASA’s requests for additional data, analysis, and data reviews to affirm the spacecraft’s safe undocking and landing capabilities."

Alternate Plan for Returning Home

NASA has emphasized that “astronaut safety remains the top priority” in its decision-making process, acknowledging the inherent risks of human spaceflight. One of the primary alternatives being considered is returning the astronauts using SpaceX’s Crew Dragon. 

This plan would involve removing two astronauts from the upcoming Crew-9 mission to make room for Wilmore and Williams.

This option underscores the lack of consensus among NASA and Boeing officials. While the extensions have been publicly framed as data-gathering exercises, internal discussions reveal deeper concerns about Starliner’s safety.

Testing Continues

From an engineering standpoint, the inability to pinpoint the root cause of the thruster failures suggests a persistent risk for further malfunctions. Mark Nappi, Boeing's vice president of the Starliner program, acknowledged the challenges during a press conference on July 25, stating that testing had led to "very significant" findings that are "likely the root cause." Despite these insights, a definitive solution remains elusive.

"We're going to continue to take that hardware apart so that we can finally prove this," Nappi said.

The Commercial Crew Program

Earlier this week, the Commercial Crew Program Control Board met to discuss Starliner’s return. These Program Control Boards (PCBs) are a standard part of NASA’s decision-making process, designed to elevate any risks to the agency’s highest levels of authority. The PCB, chaired by Commercial Crew program manager Steve Stich, did not reach a decision on whether to proceed with a flight readiness review, leaving the next major agency step in limbo.

Return planning will continue into the coming weeks, with NASA anticipating further PCB meetings to address this issue. However, the lack of a concrete resolution highlights the complexity of the situation and the stakes involved.

Starliner Record in Question

This mission was intended to demonstrate Boeing’s capability to conduct lengthy crewed missions to and from the ISS, a crucial component of NASA's Commercial Crew Program. However, the mission has turned into a costly debacle, casting doubt on Boeing’s future in the program.

Boeing’s losses have already exceeded $1.5 billion, with the current thruster issues adding to a series of setbacks and delays. The company's repeated challenges call into question its ability to fulfill its commitments under NASA’s Commercial Crew Program.

NASA’s Decision

NASA's decision on how to proceed with the return of Wilmore and Williams carries significant implications. Allowing the astronauts to return on Starliner would involve a calculated risk, as a failure during reentry could endanger their lives and lead to severe repercussions for Boeing’s contract with NASA.

Conversely, if NASA opts to bring the astronauts back using SpaceX’s Crew Dragon and sends Starliner home empty, it would be a tacit vote of no confidence in Boeing. Such a decision might prompt Boeing to reconsider its involvement in the program.

Alternatively, if NASA takes the SpaceX option and Starliner returns home without incident, the agency might face criticism for being overly cautious in a situation it previously claimed was not a significant risk.

The Starliner capsule “Calypso” mission has become a pivotal moment in the partnership between NASA and Boeing.