Following the Ahmedabad crash of Air India flight AI171, serious concerns have resurfaced about the structural safety of Boeing’s 787 Dreamliner aircraft. Former Boeing engineer Sam Salehpour had earlier raised red flags, claiming that the company used shortcuts in assembling key parts of the aircraft—creating microscopic gaps that could eventually lead the jet to break apart mid-air after a few thousand flights.
Salehpour alleged that Boeing assembles the Dreamliner by producing components separately and then joining them improperly, which compromises the aircraft’s structural integrity. These warnings led the U.S. Federal Aviation Administration (FAA) to initiate a formal investigation in April 2024. At the time, Boeing defended the Dreamliner’s safety, asserting there was no “immediate flight safety issue.”
While the Dreamliner series has previously experienced operational issues, the Ahmedabad incident is its most catastrophic. According to the Aviation Safety Network, earlier Dreamliner incidents hadn’t resulted in fatalities. In contrast, Boeing’s troubled 737 MAX aircraft has been involved in two major crashes (2018 and 2019), claiming 346 lives. Another serious event involving a 737 MAX 9 in January 2024—where a panel blew out mid-flight on an Alaska Airlines plane—added to growing concerns about Boeing’s safety protocols.
Boeing recently reached an out-of-court settlement with the U.S. Department of Justice, aiming to avoid criminal liability for the 737 MAX crashes. Under the agreement, Boeing would avoid a criminal conviction but must admit to obstructing federal oversight, pay fines, contribute to a compensation fund for victims’ families, and commit to investing in safety reforms. However, the deal still requires court approval and is being opposed by several victims’ families.
Mounting safety concerns and regulatory pressure have already led to the resignation of Boeing CEO Dave Calhoun, signaling deepening turbulence for the aviation giant.
