NASA’s Boeing Crew Flight Test Stacking Up For Launch

Crews raise a United Launch Alliance Atlas V rocket to a vertical position at the Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday, Feb. 21, 2024.
Crews raise a United Launch Alliance Atlas V rocket to a vertical position at the Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday, Feb. 21, 2024. Photo credit: NASA/Frank Michaux

NASA, Boeing, and ULA (United Launch Alliance) are readying the rocket that will launch the first crewed flight of the Starliner spacecraft to the International Space Station as part of the agency’s Commercial Crew Program.

A United Launch Alliance Atlas V rocket stands vertical, awaiting integration with the rocket’s Centaur upper stage and Boeing’s CST-100 Starliner after moving inside the Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday, Feb. 21, 2024.
A United Launch Alliance Atlas V rocket stands vertical, awaiting integration with the rocket’s Centaur upper stage and Boeing’s CST-100 Starliner after moving inside the Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida on Wednesday, Feb. 21, 2024. Photo credit: NASA/Frank Michaux

The ULA Atlas V rocket was moved into the company’s Vertical Integration Facility at Space Launch Complex-41 at Cape Canaveral Space Force Station in Florida, which starts the preparations for its stacking operations ahead of NASA’s Boeing Crew Flight Test.

The rocket’s main stage was transferred from the nearby Advanced Spaceflight Operations Center to the integration facility Wednesday, Feb. 21, where it will await integration with the rocket’s upper Centaur stage and Starliner. The spacecraft will carry NASA astronauts Suni Williams and Butch Wilmore to the orbiting laboratory for a short stay of about one to two weeks before returning to a landing site in the southwest United States.

The mission will test the end-to-end capabilities of the Starliner system, including launch, docking, and a return to Earth. After successful completion of the mission, NASA will begin the final process of certifying Starliner and its systems for crewed rotation missions to the space station.

NASA and Boeing are targeting no earlier than late April for launch. Starliner completed two uncrewed flight tests, including Orbital Flight Test-2, which docked to the space station on May 21, 2022, and provided valuable data leading up to its first crewed flight.

Details about the mission and NASA’s Commercial Crew Program can be found by following the commercial crew blog, X, and Facebook.

Progress Continues Toward NASA’s Boeing Crew Flight Test to Station

The crew module and new service module for NASA's Boeing Crew Flight Test at Kennedy Space Center.
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. Photo credit: Boeing/John Grant

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.

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.

Starliner completed two uncrewed flight tests, including Orbital Flight Test-2, which docked to the space station on May 21, 2022, following a launch two days prior from Kennedy. The spacecraft remained docked to space station for four days before successfully landing at the White Sands Missile Range in New Mexico.

Follow NASA’s commercial crew blog or CFT mission blog for the latest information on progress. Details about NASA’s Commercial Crew Program can be found by following the commercial crew blog, @commercial_crew on X, and commercial crew on Facebook.

Starliner Joins Atlas V at Space Launch Complex-41

Boeing's CST-100 Starliner
Boeing’s CST-100 Starliner spacecraft rolls out from the company’s Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida on May 4, 2022, on its way to Space Launch Complex-41 at Cape Canaveral Space Force Station. Photo credit: NASA/Glenn Benson

On Wednesday, May 4, Boeing’s CST-100 Starliner was joined with the rocket that will launch the spacecraft on its way to the International Space Station on an uncrewed flight test for NASA’s Commercial Crew Program.

During the operation, Starliner rolled out of the Commercial Crew and Cargo Processing Facility (C3PF) at NASA’s Kennedy Space Center in Florida and made its way to Space Launch Complex-41 (SLC-41) at Cape Canaveral Space Force Station in preparation for the company’s second uncrewed Orbital Flight Test (OFT-2)

CST-100 Starliner and Atlas V rocket
United Launch Alliance’s Atlas V rocket and Boeing’s CST-100 Starliner spacecraft are fully assembled in preparation for an integrated systems test. Photo credit: United Launch Alliance

Starliner was raised and carefully placed onto the rocket and now is fully assembled and ready for an integrated systems test, a tip-to-tail electrical check of the 172-foot-tall Atlas V and Starliner stack.

OFT-2 is scheduled to launch Thursday, May 19, to demonstrate the system’s human transportation capabilities.

About 24 hours after launch, Starliner will rendezvous and dock to the space station and then return to Earth five to 10 days later. The test is the last flight before the Starliner system launches American astronauts on the Crew Flight Test (CFT) to the microgravity laboratory – the spacecraft’s first flight test with crew on board. Potential launch windows for CFT are under review and will be determined after a safe and successful OFT-2.

More details about the mission and NASA’s commercial crew program can be found by following the commercial crew blog@commercial_crew on Twitter, and commercial crew on Facebook.