Boeing’s Dreamliner Faces Renewed Scrutiny After Fatal Air India Crash
New Delhi / Washington, June 13, 2025 – Boeing’s long-haul flagship, the 787 Dreamliner, is once again under intense scrutiny after Air India flight AI 171 tragically crashed on Thursday, marking the first-ever fatal accident involving the 787-8 model since its commercial debut in 2011.
The aircraft, over 11 years old with more than 41,000 flight hours and nearly 8,000 completed cycles, went down in what has become the third fatal Boeing plane crash globally in the last seven years. The crash has reignited safety concerns tied to the Dreamliner’s history of technical flaws, whistleblower allegations, and regulatory investigations.
Following the incident, Boeing’s shares dropped nearly 8% in pre-market trading on the New York Stock Exchange, highlighting investor anxiety over the company’s troubled safety track record.
A History of Red Flags
The Dreamliner has faced significant technical issues since inception. In 2013, the entire global fleet was grounded after battery fires broke out on two separate 787s—one on the tarmac in Boston and another mid-air over Japan. Boeing had to redesign the lithium-ion battery system before the aircraft was cleared to fly again.
More recently, in March 2024, a Boeing 787-9 operated by LATAM Airlines suffered a sudden in-flight nosedive, injuring 50 passengers. Investigations traced the incident to a faulty cockpit seat mechanism.
The current crash adds to growing industry concerns over Boeing’s manufacturing practices. The U.S. Federal Aviation Administration (FAA) has maintained close oversight of the company, particularly following two catastrophic 737 Max crashes in 2018 and 2019 and a mid-air door plug blowout on an Alaska Airlines Max jet in early 2024.
Whistleblower Warnings Ignored?
Internal whistleblowers have raised red flags about Dreamliner production. Boeing engineer Sam Salehpour alleged that some fuselage sections on the 787s were improperly joined, leaving “tiny gaps” that could compromise the aircraft’s structural integrity and reduce its lifespan. He further revealed that factory workers at times jumped on components to force them into alignment, a method he called “dangerous and unprofessional.”
John Barnett, a former Boeing quality manager at the company’s Charleston, South Carolina plant, also made serious allegations about substandard parts being installed on early-model Dreamliners—including those delivered to Air India, which became the first airline to operate the Charleston-built jets in 2012.
These accusations prompted the FAA to halt Dreamliner deliveries from 2021 to 2023 while conducting extensive reviews of Boeing’s production practices. Although deliveries have since resumed with updated inspection protocols, Salehpour’s legal team insists that the fuselage issues remain unresolved.
India’s Growing Ties with Boeing
Despite the mounting safety concerns, Indian carriers continue to place significant trust—and orders—with Boeing. Air India currently operates 34 Dreamliners and has another 44 aircraft either on order or under negotiation. Akasa Air, another Indian carrier, has also placed large orders with Boeing. Meanwhile, IndiGo, which primarily flies Airbus aircraft, has supplemented its fleet with two leased Boeing 777s and one 787.
IndiGo is currently operating one of the youngest airline fleets in the world, with an average aircraft age of just four years.
Boeing Responds
In a brief statement following Thursday’s crash, Boeing said, “We are in close contact with Air India and stand ready to provide full support.” The company did not comment further on the implications of the crash for its ongoing production or delivery schedules.
As investigations into the cause of the AI 171 crash begin, aviation experts warn that Boeing’s reputation is once again at a crossroads. With safety under the global spotlight and a growing number of carriers dependent on its aircraft, the company may soon face renewed regulatory and commercial pressure to overhaul its production standards.
