Air India flight AI171 crash in Ahmedabad renews scrutiny of Boeing’s troubled Dreamliner programme
The tragic crash of Air India Flight 171, just 30 seconds after takeoff, has shocked the world. At least 270 lives were lost, and while investigators are still trying to determine the cause, the spotlight has turned to the aircraft involved — the Boeing 787 Dreamliner.
The Dreamliner’s Reputation
For nearly 15 years, the 787 Dreamliner was considered one of the safest and most advanced planes in the sky. With over a billion passengers flown and more than 1,100 in service globally, it had a spotless fatal accident record — until now.
The Dreamliner was Boeing’s answer to rising fuel costs in the early 2000s. Built with lightweight carbon fiber instead of traditional aluminum and featuring ultra-efficient engines, it promised 20% better fuel efficiency and lower noise levels. It also allowed airlines to offer more direct, long-distance routes between smaller cities, moving away from the old “hub and spoke” model of air travel.
A History of Problems Behind the Scenes
Despite its stellar public image, the 787 has been troubled by quality concerns behind closed doors. Early on, battery fires forced the plane to be grounded worldwide in 2013. While Boeing resolved the issue and the Dreamliner returned to service, whistleblower warnings never truly stopped.
Boeing set up a new assembly line in South Carolina to reduce costs — but this move also introduced quality control issues. Former employees, including the late John Barnett, raised alarms about serious lapses: missing or faulty parts, metal shavings near key wiring, and pressure to ignore defects just to keep production moving. One FAA audit even confirmed several of these concerns.
Whistleblower Warnings Grow Louder
Barnett and others, like Cynthia Kitchens and current Boeing employee Sam Salehpour, have all painted a worrying picture. Salehpour told U.S. lawmakers in 2024 that shortcuts in 787 production could lead to catastrophic failures. He claimed over 1,000 aircraft might be affected by structural flaws due to tiny gaps in fuselage joints.
Boeing has pushed back, saying all concerns have been investigated by the FAA and pose no safety risks. The company insists the Dreamliner will last for decades.
The Bigger Picture
Boeing’s reputation has already taken a hit from past crashes involving its 737 Max jets. Now, even as CEO Kelly Ortberg works to rebuild trust with regulators and overhaul internal processes, concerns remain.
Still, experts point out the Dreamliner’s strong safety record. Aviation analyst Richard Aboulafia says any serious problems would likely have surfaced by now, given the 787 has flown for over a decade with no fatal accidents — until the recent Air India tragedy.
The specific cause of the crash in Ahmedabad is still unknown. Some speculate issues like water leaks into electrical systems may have played a role, but there’s no confirmation yet. What’s certain is that the world is watching closely as investigators work to provide answers.
For Now, the 787 Is Still Flying
Despite everything, many aviation experts still trust the Dreamliner. As Scott Hamilton from Leeham Company put it: “Based on what we do know about the plane, I would not hesitate to get on board a 787.”
The final verdict will depend on what the ongoing investigation uncovers. Until then, the Dreamliner remains both a symbol of innovation — and a subject of serious concern.
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