In 2024, Boeing engineer Sam Salehpour raised serious concerns about the structural integrity of the Boeing 787 Dreamliner, alleging that the company took shortcuts during manufacturing, including misaligned fuselage sections and improper fastening, which could lead to catastrophic failures over time. He claimed these issues, affecting over 1,000 Dreamliners, involved gaps in fuselage joints and forced alignment practices, such as workers physically jumping on parts, potentially causing premature fatigue in the aircraft’s composite materials. Salehpour’s allegations, detailed in interviews with The New York Times and a formal complaint to the Federal Aviation Administration (FAA), prompted an ongoing FAA investigation. He also testified before a US Senate subcommittee in April 2024, warning that these flaws could result in the aircraft “breaking apart” after repeated flights. Another whistleblower, Richard Cuevas, filed complaints in 2024, alleging issues with the forward pressure bulkhead, critical for managing flight pressure. Boeing denied these claims, asserting extensive testing showed no immediate safety risks and that the Dreamliner was safe, while the FAA confirmed the aircraft met current safety standards.
On June 12, 2025, Air India Flight AI171, a Boeing 787-8 Dreamliner carrying 242 people, crashed shortly after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, marking the first fatal crash of a 787 since its 2011 debut. The cause remains under investigation by Air India and the Directorate General of Civil Aviation (DGCA), with no confirmed link to the whistleblowers’ claims. Boeing has expressed readiness to support the investigation. The crash has reignited scrutiny of Boeing’s safety culture, especially following prior incidents like the 737 MAX crises in 2018 and 2019.