NASA's inspector general warned that Boeing's Starliner crew capsule may not achieve operational certification until 2027, a full decade behind the original 2017 target. The audit reveals persistent technical problems from Starliner's 2024 crewed test flight, which stranded NASA astronauts Butch Wilmore and Suni Williams on the International Space Station for nine months instead of the planned eight days.

NASA classified the 2024 flight as a "Type A" mishap and stripped Boeing of two crew rotation missions, reducing the contract by about $500 million. The agency paid $17 million to SpaceX for accelerated Crew Dragon flights to maintain ISS staffing. Starliner-1 will now fly cargo only, meaning NASA must purchase an additional $300 million crew mission to cover the shortfall.

Technical issues persist, including helium leaks, overheating thrusters, and parachute anomalies that investigators haven't fully resolved. NASA and Boeing's overconfidence in heritage systems and unrealistic scheduling contributed to these problems. Boeing must secure launch slots on United Launch Alliance's Atlas V rocket while competing for limited ISS docking ports.

SpaceX achieved crew certification in 2020 while Starliner experienced repeated delays, including a failed 2019 uncrewed test. The inspector general questioned nearly $128 million in payments to Boeing for the uncertain Starliner-3 mission, highlighting the program's mounting costs and schedule setbacks.