An anonymous reader quotes a report from CBC News: Stranded astronauts Butch Wilmore and Suni Williams said Friday it was hard to watch their Boeing capsule return to Earth without them. It was their first public comments since last week's return of the Boeing Starliner capsule that took them to the International Space Station in June. They remained behind after NASA determined the problem-plagued capsule posed too much risk for them to ride back in. "That's how it goes in this business," said Williams, adding that "you have to turn the page and look at the next opportunity." Wilmore and Williams are now full-fledged station crew members, chipping in on routine maintenance and experiments. They, along with seven others on board, welcomed a Soyuz spacecraft carrying two Russians and an American earlier this week, temporarily raising the station population to 12, a near record. NASA astronauts Butch Wilmore and Suni Williams spoke to the press on Friday for the first time since their Boeing Starliner capsule returned to Earth without them. The two, who have been on the International Space Station since June 6, said they are taking the mission's unexpected extension into 2025 in stride -- even if it means they've had to change their voting plans. The transition to station life was "not that hard" since both had previous stints there, said Williams, who will soon take over as station commander. "This is my happy place. I love being up here in space," she said. The two Starliner test pilots -- both retired U.S. navy captains and longtime NASA astronauts — will stay at the orbiting laboratory until late February. They have to wait for a SpaceX capsule to bring them back. That spacecraft is due to launch later this month with a reduced crew of two, with two empty seats for Wilmore and Williams for the return leg. The duo said they appreciated all the prayers and well wishes from strangers back home. Wilmore said he will miss out on family milestones such as being around for his youngest daughter's final year of high school. The astronauts, who prepared for eight days in space, will now be up there for eight months, which could have a greater impact on the body. "It is a bit of a change from a sprint to a marathon," said Dr. Adam Sirek of the Canadian Society of Aerospace Medicine.

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An anonymous reader quotes a report from the Associated Press: A daredevil billionaire rocketed back into orbit Tuesday, aiming to perform the first private spacewalk and venture farther than anyone since NASA's Apollo moonshots. Unlike his previous chartered flight, tech entrepreneur Jared Isaacman shared the cost with SpaceX this time around, which included developing and testing brand new spacesuits to see how they'll hold up in the harsh vacuum. If all goes as planned, it will be the first time private citizens conduct a spacewalk, but they won't venture away from the capsule. Considered one of the riskiest parts of spaceflight, spacewalks have been the sole realm of professional astronauts since the former Soviet Union popped open the hatch in 1965, closely followed by the U.S. Today, they are routinely done at the International Space Station. Isaacman, along with a pair of SpaceX engineers and a former Air Force Thunderbirds pilot, launched before dawn aboard a SpaceX Falcon 9 rocket from Florida. The spacewalk is scheduled for Thursday, midway through the five-day flight. But first the passengers are shooting for way beyond the International Space Station -- an altitude of 870 miles (1,400 kilometers), which would surpass the Earth-lapping record set during NASA's Project Gemini in 1966. Only the 24 Apollo astronauts who flew to the moon have ventured farther. The plan is to spend 10 hours at that height -- filled with extreme radiation and riddled with debris -- before reducing the oval-shaped orbit by half. Even at this lower 435 miles (700 kilometers), the orbit would eclipse the space station and even the Hubble Space Telescope, the highest shuttle astronauts flew. All four wore SpaceX's spacewalking suits because the entire Dragon capsule will be depressurized for the two-hour spacewalk, exposing everyone to the dangerous environment. Isaacman and SpaceX's Sarah Gillis will take turns briefly popping out of the hatch. They'll test their white and black-trimmed custom suits by twisting their bodies. Both will always have a hand or foot touching the capsule or attached support structure that resembles the top of a pool ladder. There will be no dangling at the end of their 12-foot (3.6-meter) tethers and no jetpack showboating. Only NASA's suits at the space station come equipped with jetpacks, for emergency use only.

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The European Space Agency (ESA) has successfully 3D printed the first metal part aboard the International Space Station. This achievement marks a significant advancement in in-orbit manufacturing that could enable the production of essential spare parts and tools for future long-duration space missions. "The first metal shape was produced in August, and three more are planned as part of the experiment," notes The Register. "All four will eventually be returned to Earth for analysis -- two to ESA's technical center, ESTEC, in the Netherlands, one to the agency's astronaut training center in Cologne, and the last sample to the Technical University of Denmark." From the report: During a panel discussion following the UK premiere of Fortitude, a film about the emerging commercial space industry, Advenit Makaya, Advanced Manufacturing Engineer at ESA, remarked on the potential for recycling space debris in the process rather than having to rely on raw materials launched to the ISS. Rob Postema, ESA Project Manager for Metal 3D, told The Register that the agency was indeed looking at "circular" solutions in its drive for greater sustainability. However, don't hold your breath for putting bits of space garbage into one end and getting shiny metal parts out of the other: "A timeline is difficult to indicate, some early results are achieved with ground activities, ready to evaluate solutions in space." The printer is overseen from the ground and operated for around four hours per day. The ground team has to check each layer via images and a scan of the surface area; printing a sample can take 10-25 days. However, Postema said: "Through automated control of the printing process as well as continuous operations, this can be substantially reduced." Knick-knacks from orbits are all well and good, but could something more substantial be produced? Yes, although not with this demonstrator, which can print to the outer dimensions of a soft drink can. Postema noted that while the demonstrator could manage smaller parts, either as a single unit or as part of larger structures, "there are definitely opportunities to create 3D shapes and parts with this technology larger than what we have done with this Technology Demonstrator."

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Boeing's "beleaguered" Starliner spacecraft "successfully landed in New Mexico just after midnight Eastern time," reports NPR: After Starliner made a picture-perfect landing, Stich told reporters that the spacecraft did well during its return flight. "It was a bullseye landing," he said. "It's really great to get the spacecraft back...." He said while he and others on the team felt happy about the successful landing, "there's a piece of us, all of us, that we wish it would've been the way we had planned it" with astronauts on board when it landed... Now that Starliner is back on the ground, Boeing and NASA will further analyze the thrusters to see if modifying the spacecraft or how it's flown could keep the thrusters from overheating in the future. Futurism explains why NASA wanted an uncrewed Starliner flight: While attempting to duplicate the issue at NASA's White Sands Test Facility in New Mexico, engineers eventually found what appeared to be the smoking gun, as SpaceNews' Jeff Foust details in a detailed new breakdown of the timeline. A Teflon seal in a valve known as a "poppet" expanded as it was being heated by the nearby thrusters, significantly constraining the flow of the oxidizer — a disturbing finding, because it greatly degraded the thrusters' performance. Worse, without being able to perfectly replicate and analyze the issue in the near vacuum of space, engineers weren't entirely sure how the issue was actually playing out in orbit... While engineers found that the thrusters had returned to a more regular shape after being fired in space, they were worried that similar deformations might take place during prolonged de-orbit firings. A lot was on the line. Without perfect control over the thrusters, NASA became worried that the spacecraft could careen out of control. "For me, one of the really important factors is that we just don't know how much we can use the thrusters on the way back home before we encounter a problem," NASA associate administrator for space operations Ken Bowersox said, as quoted by SpaceNews. Now CBS News reports that "the road ahead is far from clear" for Starliner: The service module was jettisoned as planned before re-entry, burning up in the atmosphere, and engineers will not be able to examine the hardware to pin down exactly what caused the helium leaks and degraded thruster performance during the ship's rendezvous with the station. Instead, they will face more data analysis, tests and potential redesigns expected to delay the next flight, with or without astronauts aboard, to late next year at the earliest. "Even though it was necessary to return the spacecraft uncrewed, NASA and Boeing learned an incredible amount about Starliner in the most extreme environment possible," Ken Bowersox, space operations director at NASA Headquarters, said in a statement. "NASA looks forward to our continued work with the Boeing team to proceed toward certification of Starliner for crew rotation missions to the space station," Bowersox added. In any case, the successful landing was a shot in the arm for Boeing engineers and managers, who insisted the Starliner could have safely brought Wilmore and Williams back to Earth. Steve Stich, manager of NASA's commercial crew program, agreed that if the crew had been on board "it would have been a safe, successful landing." Two details about the astronauts now waiting for their February return flight from the International Space Station. NPR reports that "in case the space station suffers an emergency that forces an evacuation before that capsule arrives, the station's crew had to jerry-rig two extra seats in a different SpaceX spacecraft that's currently docked there." Space.com reports that when the uncrewed Starliner returned, "Among the gear that it carried home were the 'Boeing Blue' spacesuits that Williams and Wilmore wore aboard the capsule. The astronauts have no need for them now. "The suits are not compatible," Steve Stich, manager of NASA's Commercial Crew Program, said during a press conference on Wednesday (Sept. 4). "So the Starliner suits would not work in Dragon, and vice versa."

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An anonymous reader shared this report from Ars Technica: On Saturday NASA astronaut Butch Wilmore noticed some strange noises emanating from a speaker inside the Starliner spacecraft. "I've got a question about Starliner," Wilmore radioed down to Mission Control, at Johnson Space Center in Houston. "There's a strange noise coming through the speaker ... I don't know what's making it." [Ars Technica embeded a clip of the conversation including the rhythmic, sonar-like noise which was shared online by a Michigan-based meteorologist.] Wilmore said he was not sure if there was some oddity in the connection between the station and the spacecraft causing the noise, or something else. He asked the flight controllers in Houston to see if they could listen to the audio inside the spacecraft. A few minutes later, Mission Control radioed back that they were linked via "hardline" to listen to audio inside Starliner, which has now been docked to the International Space Station for nearly three months. Wilmore, apparently floating in Starliner, then put his microphone up to the speaker inside Starliner. Shortly thereafter, there was an audible pinging that was quite distinctive. "Alright Butch, that one came through," Mission control radioed up to Wilmore. "It was kind of like a pulsing noise, almost like a sonar ping." "I'll do it one more time, and I'll let y'all scratch your heads and see if you can figure out what's going on," Wilmore replied. The odd, sonar-like audio then repeated itself. "Alright, over to you. Call us if you figure it out."

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NASA astronauts Butch Wilmore and Suni Williams are facing challenges returning to Earth due to compatibility issues between their Boeing-designed spacesuits and SpaceX's Dragon spacecraft. Inc. Magazine reports: The space suits in question are the "intra-vehicular activity" outfits now worn by astronauts. They're simpler than the bulky extra-vehicular space suits used on space walks, and are designed to keep astronauts safe in the capsule in the very unlikely case there's a problem that causes the capsule's atmosphere to be lost. The problem is simple: Should Butch and Suni need to fly back aboard SpaceX's vehicle, their suits won't fit in Dragon's seats. [...] Boeing and SpaceX suits evolved under totally different design sensibilities. If Boeing and NASA deem Starliner unsafe for humans to fly home in, Butch and Suni must head earthward aboard a SpaceX Dragon, but their suits won't be able to plug into Dragon's systems. Like trying to plug an essentially outdated USB A socket into an iPhone's charge port, the suit connectors have different shapes, styles, and functions. The suits themselves have different systems that integrate with their own capsules for purposes like air leak checks during pre-flight testing. So if an emergency situation presents itself and astronauts have to come back to Earth before proper plans are finalized, Butch and Suni will have to return inside the cargo section of a Dragon space capsule "unsuited," according to NASA leadership who spoke on the matter in a press conference last week. Other plans include flying up suitable Dragon-connecting space suits for the two astronauts on a later mission, should Starliner be deemed incapable of bringing them back.

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An anonymous reader quotes a report from the New York Times: For weeks, NASA has downplayed problems experienced by Starliner, a Boeing spacecraft that took two astronauts to the International Space Station in June. But on Wednesday, NASA officials admitted that the problems with the spacecraft were more serious than first thought and that the astronauts may not travel home on the Boeing vehicle, after all. The agency is exploring a backup option for the astronauts, Suni Wiliams and Butch Wilmore, to hitch a ride back to Earth on a vehicle built by Boeing's competitor SpaceX instead. Their stay in orbit, which was to be as short as eight days, may extend into next year. "We could take either path," Ken Bowersox, NASA's associate administrator for the space operations mission directorate, said during a news conference on Wednesday. "And reasonable people could pick either path." NASA and Boeing officials had maintained that the crew that launched with Starliner on its first crewed test flight was not stranded in space. Ms. Williams and Mr. Wilmore have spent two months aboard the orbital outpost while engineers continue to analyze data about the faulty performance of several of the Starliner's thrusters when it approached for docking. Under the contingency plan, a SpaceX Crew Dragon capsule would travel to the space station with two astronauts instead of its planned crew of four. Ms. Williams and Mr. Wilmore would then join as full-time members of the space station crew for a half-year stay, returning on the Crew Dragon around next February. "In the last few weeks, we have decided to make sure we have that capability there, as our community, I would say, got more and more uncomfortable," said Steve Stich, the manager of the commercial crew program at NASA. NASA officials said no decision had been made yet.

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joshuark shares a report from The Verge: NASA researchers have successfully tested laser communications in space by streaming 4K video footage originating from an airplane in the sky to the International Space Station and back. The feat demonstrates that the space agency could provide live coverage of a Moon landing during the Artemis missions and bodes well for the development of optical communications that could connect humans to Mars and beyond. NASA normally uses radio waves to send data and talk between the surface to space but says that laser communications using infrared light can transmit data 10 to 100 times faster than radios. "ISS astronauts, cosmonauts, and unwelcomed commercial space-flight visitors can now watch their favorite porn in real-time, adding some life to a boring zero-G existence," adds joshuark. "Ralph Kramden, when contacted by Ouiji board, simply spelled out 'Bang, zoom, straight to the moon!'"

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