UGH: Component failure in NASA’s deep-space crew capsule could take months to fix.

In early November, engineers at Lockheed Martin working on Orion noticed that a power component inside the vehicle had failed, according to an internal email and an internal PowerPoint presentation seen by The Verge. The component is within one of the spacecraft’s eight power and data units, or PDUs. The PDUs are the “main power/data boxes,” for Orion according to the email, responsible for activating key systems that Orion needs during flight.
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Replacing the PDU isn’t easy. The component is difficult to reach: it’s located inside an adapter that connects Orion to its service module — a cylindrical trunk that provides support, propulsion, and power for the capsule during its trip through space. To get to the PDU, Lockheed Martin could remove the Orion crew capsule from its service module, but it’s a lengthy process that could take up to a year. As many as nine months would be needed to take the vehicle apart and put it back together again, in addition to three months for subsequent testing, according to the presentation.

Lockheed has another option, but it’s never been done before and may carry extra risks, Lockheed Martin engineers acknowledge in their presentation. To do it, engineers would have to tunnel through the adapter’s exterior by removing some of the outer panels of the adapter to get to the PDU. The panels weren’t designed to be removed this way, but this scenario may only take up to four months to complete if engineers figure out a way to do it.

Later today or this weekend, SpaceX will attempt the highest flight yet for the eighth prototype of the company’s Starship vehicle.