The Boeing Starliner spacecraft has technical issues that are delaying its first crewed test flight. The two problems are with the parachutes and internal tape. The current forecast launch date is no earlier than April 2024.

Parachute Concerns

During certification reviews, engineers found that small fabric sections called “soft links” connecting Starliner’s parachutes to the capsule had lower load limits than expected. These soft links failed at lower stresses when retested.

The soft links are part of what attaches the main parachutes to Starliner. They take force during descent.

The lower limits decrease the overall safety factor in the parachute system. This could be risky if one parachute fails, putting more load on the others.

Flammable Tape Issue

Boeing also discovered that P-213 glass cloth tape used extensively to wrap wire harnesses inside Starliner has a flammable acrylic adhesive.

This tape protects cables from chafing throughout the capsule. There are hundreds of feet of wiring wrapped in it.

If insulation was damaged, exposing conductors, a short could ignite the tape adhesive in some cases. The risk depends on the wire’s power level.

Impact on Program

Resolving all issues is essential before launching astronauts.

Boeing must now take time to redesign parachutes, apply tape fixes, and get NASA approval. The next target is not earlier than April 2024, but further delays are likely.

Boeing bears the financial burden of repairs due to its fixed price contract. Delays have already cost the company nearly $900 million.

More delays risk impacting NASA’s access to the ISS before its retirement around 2030. Getting Starliner operational soon is critical.