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Boeing Starliner spacecraft successfully returns to flight 29 months after ill-fated debut
More than three years after SpaceX’s Crew Dragon spacecraft first safely reached orbit and almost three and a half years after Boeing’s Starliner crew capsule’s ill-fated launch debut, Boeing has finally returned to flight and made it farther than ever before towards a successful test flight.
Almost ten months after Boeing’s first attempt at Starliner’s second uncrewed Orbital Flight Test (OFT-2 #1), the stars aligned. As expected, the United Launch Alliance’s Atlas V rocket lifted off on time at 6:54 pm EDT (22:54 UTC) on Thursday, May 19th, ascending from Cape Canaveral Space Force Station (CCSFS) Launch Complex 41 (LC-41) without issue. After a four and a half minute burn, the Atlas V booster – powered by a Russian-built RD-180 engine – separated and the Centaur upper stage – powered by two Aerojet Rocketdyne RL-10 engines – took over.
Another six minutes later, Centaur shut down and Starliner ultimately separated from the rocket a bit less than 12 minutes after liftoff. Unlike SpaceX’s Crew Dragon, though, Starliner separated from its launch vehicle before reaching orbit – a task Boeing engineers chose to reserve for the spacecraft itself to limit stress on the spacecraft and crew in the event of a high-altitude abort. However, that design decision also adds significant risk in other ways and – after the spacecraft’s extremely poor performance during its first launch attempt – turns a Starliner launch into a sort of 30-minute cliffhanger.
While just a hair shy of true orbit, Starliner’s suborbital launch trajectory means that whether or not it wants to, the spacecraft will reenter Earth’s atmosphere about an hour after liftoff if it can’t complete a minute-long orbital insertion burn. In the case of OFT-2, that burn came about 31 minutes after liftoff and was thankfully successful, inserting Starliner into a stable, circular orbit and undoubtedly triggering a massive wave of relief for all employees involved. From that stable orbit, Starliner can finally begin to prepare to rendezvous with the International Space Station (ISS) for the first time ever.
The story of Starliner’s tortured orbital flight test (OFT) campaign began in earnest on December 20th, 2019, when an uncrewed prototype of the Boeing spacecraft first attempted to launch to the International Space Station (ISS) atop a United Launch Alliance (ULA) Atlas V rocket. Infamously, a major software bug that could have been easily detected with even the most basic integrated hardware-in-the-loop prelaunch testing caused Starliner to lose control the moment it separated from Atlas V. Only through a heroic last-second effort was Boeing able to insert Starliner into orbit and prevent the spacecraft from reentering prematurely, which would have likely destroyed it. After hundreds of seconds of unplanned burns of its many attitude control thrusters, Starliner no longer had enough propellant to safely reach the ISS.
Boeing would later correct another completely unrelated software bug mere hours before Starliner’s planned reentry and recovery. If undetected, it could have caused the spacecraft’s capsule and service sections to crash into each other shortly after separation, potentially damaging the capsule’s heat shield and dooming it to destruction during reentry. Had astronauts been aboard, either of the two software bugs could have potentially resulted in crew fatalities and total mission failure. Instead, through a combination of sheer luck and a quick emergency response from Boeing and NASA teams, the spacecraft was saved and recovered in New Mexico.
On a positive note, aside from raising deep and foreboding questions about Boeing’s software development and integrating testing capabilities and NASA’s inept and inconsistent oversight, OFT-1 did still demonstrate that Starliner was able to reach orbit, operate in space, deorbit, survive atmospheric reentry, and land softly under parachutes.
However, the problems were about to continue and spread beyond software. On July 30th, 2021, shortly before a different uncrewed Starliner was scheduled to reattempt the first Orbital Flight Test, the launch was aborted. Eventually, Boeing and NASA reported that 13 of Starliner’s 24 main oxidizer valves had failed to open during a prelaunch test just a few hours before liftoff. The resulting investigation ultimately concluded that the Aerojet Rocketdyne-supplied valves had a faulty design and that Boeing had failed to properly insulate those valves from humidity and water intrusion. It also delayed the next OFT-2 launch attempt by almost ten months.
But finally, after almost 30 months of work to rectify those software and hardware failures, Starliner has intentionally reached a stable orbit without running into a major problem – certainly cause for some amount of optimism. Still, safely rendezvousing and docking with the ISS may be the biggest and riskiest challenge Starliner has faced yet and Boeing will be attempting the feat for the first time in its modern history. Starliner is expected to begin proximity operations around 3 pm EDT on May 20th. If the first attempt is perfect, docking could occur as early as 7:10 pm EDT.
Ultimately, even if Boeing is now more than three years behind SpaceX, whose Crew Dragon spacecraft first reached orbit and the ISS in March 2019 and launched its first astronauts in May 2020, it’s essential that NASA has two redundant crew vehicles available to carry its astronauts to and from the station. SpaceX’s extraordinary success and heroic efforts have allowed the company to singlehandedly ensure NASA access to the ISS since November 2020, but no complex system is perfect and even a failure outside of SpaceX’s control could trigger a long delay that could threaten NASA’s uninterrupted presence on the International Space Station.
NASA has contracts with SpaceX to maintain that uninterrupted presence at the ISS through Crew Dragon’s Crew-7 mission, which could launch as early as September 2023 and would then return to Earth around March 2024. If OFT-2 is completed without significant issue, Boeing’s next priority is Starliner’s Crew Flight Test (CFT), a crewed launch debut that could happen before the end of 2022.
After that, Starliner’s first operational crew launch could potentially occur in Q1 2024, just before Crew Dragon’s Crew-7 recovery. Following Crew Dragon’s near-flawless uncrewed test flight, it took another 14 months for NASA and SpaceX to proceed to Demo-2, Dragon’s Crew Flight Test equivalent. Dragon’s first operational astronaut launch occurred in November 2020, 20 months after its uncrewed demo flight. If NASA follows a similar path for Starliner, that meshes well with an operational debut in early 2024.
Elon Musk
Tesla shows what Roadster drivers will see on screen before thruster activation
Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.
Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”
The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.
Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.
That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.
The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.
The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.
Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.
Elon Musk
Tesla reveals Optimus Academy, where robots teach themselves
Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.
Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”
The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.
Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.
The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.
Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.
The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.
Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.
Elon Musk
The Starship moon landing number NASA and Elon Musk can’t agree on
Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.
Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.
On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”
Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”
The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.
Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.
How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.
Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.
Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.
Tesla shows what Roadster drivers will see on screen before thruster activation
Tesla reveals Optimus Academy, where robots teach themselves
