Boeing reassured the public of the 787 Dreamliner’s safety, following allegations from whistle-blower Sam Salehpour regarding structural integrity. Boeing engineers conducted tests and inspections that found no evidence of premature body failure. Salehpour claimed fuselage sections were not properly fastened, potentially leading to structural issues over time. The Federal Aviation Administration is investigating his allegations, which come after a panel came off a 737 Max earlier this year, creating more scrutiny on Boeing’s manufacturing practices.
The Boeing engineers disagreed with Salehpour’s claims, stating that extensive testing showed the vast majority of gaps in the fuselage met specifications. Even if some gaps exceeded specifications, the engineers believed they would not impact the plane’s durability. The Dreamliner underwent rigorous testing that included 165,000 “flight cycles” without showing any signs of fatigue. The plane with the most cycles, belonging to All Nippon Airways, had been through about 16,500 cycles, surpassing its expected lifespan with no issues.
Salehpour is set to testify before Congress about his concerns regarding the Dreamliner, while a separate hearing will involve experts discussing a recent F.A.A. report criticizing Boeing’s safety culture. Boeing had been investigating fuselage gap issues in the Dreamliner for about five years, finding that some did not meet specifications. This led to a pause in deliveries for inspections and changes to address the problem. Approximately 1 percent of gaps failed to meet specifications, but research and testing indicated these larger gaps did not pose durability risks.
Boeing emphasized that thorough maintenance checks on 671 Dreamliners had found no signs of premature fatigue, despite some gaps not meeting specifications. The company stated that planes currently in operation did not require modifications based on the testing and inspections conducted. Salehpour’s lawyer cautioned against blindly trusting Boeing’s assertions about the Dreamliner’s safety, calling for independent validation of any data provided. The company’s reassurance of the Dreamliner’s safety comes amidst ongoing scrutiny over its manufacturing practices and regulatory oversight.
