WASHINGTON, United States
A newly released internal review from NASA has outlined a series of significant technical and management concerns with the Boeing Starliner program, raising fresh questions about the spacecraft’s readiness for routine astronaut missions and highlighting ongoing challenges in one of the agency’s flagship commercial partnerships.
The report, based on post-flight data and engineering assessments, details problems ranging from propulsion system anomalies to broader quality control and oversight issues. Officials emphasized that while progress has been made, additional testing and corrective actions will be required before the spacecraft can achieve full operational certification for regular crew transport to the International Space Station.
Among the most serious concerns identified were irregularities in the spacecraft’s thruster performance and helium leaks within the propulsion system. Engineers noted that these issues affected maneuvering capability during recent missions and required extensive troubleshooting to ensure safe docking and return operations. NASA officials said resolving propulsion reliability will be a top priority moving forward.
The review also pointed to past software integration problems that have contributed to delays since the program’s early test flights. Although updates and fixes have been implemented over time, the agency said continued verification is needed to confirm system stability under a full range of mission conditions.
Beyond hardware challenges, investigators highlighted shortcomings in manufacturing oversight and quality assurance processes, noting the need for stronger inspection protocols and improved coordination between engineering teams. The report also referenced broader program management difficulties, including schedule delays and rising costs, which have complicated efforts to bring the spacecraft fully online.
Developed under NASA’s Commercial Crew Program, Starliner was intended to provide a second independent system for transporting astronauts alongside SpaceX’s Crew Dragon, ensuring redundancy for missions to orbit. However, the spacecraft has faced multiple setbacks since its first uncrewed test flight in 2019, including software errors, valve issues, and launch postponements.
NASA stressed that astronaut safety remains the agency’s highest priority and said the spacecraft will not be cleared for routine crewed flights until all critical issues are resolved and performance is verified through additional testing. Officials described the findings as part of a normal but rigorous review process designed to identify risks early and strengthen mission reliability.
The report is expected to have financial and competitive implications for Boeing, which has already absorbed significant costs tied to program delays and technical fixes. Industry analysts say the challenges highlight the complexity of human spaceflight development and the importance of strict oversight in commercial partnerships.
Despite the setbacks, NASA reaffirmed its commitment to maintaining two operational crew transport systems to ensure flexibility and resilience in future missions. The agency and Boeing are expected to continue working closely to implement engineering improvements, conduct further testing, and establish a timeline for the spacecraft’s next flight opportunities.
For now, the findings underscore both the progress achieved and the hurdles that remain as the Starliner program works toward meeting the rigorous safety and performance standards required for human spaceflight.
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