Air India crash puts Boeing 787 under scrutiny again: Whistleblower warned of ‘ticking time bomb’

Air India flight AI-171, a Boeing 787-8 Dreamliner carrying 242 passengers, crashed shortly after taking off from Ahmedabad on Thursday, killing all passengers on board.

The aircraft, en route to London Gatwick, went down near a residential neighborhood, sending thick plumes of smoke into the air. Emergency crews responded swiftly, transporting injured passengers to local hospitals as rescue efforts got underway immediately.

According to a MoneyControl report, the incident marks the first-ever total loss of a Boeing 787 since its commercial debut in 2011.

Once celebrated as a flagship of next-generation aviation, the Dreamliner has since faced persistent issues, including technical malfunctions, production delays, and ongoing safety concerns.

What is the Boeing 787 Dreamliner?

The Boeing 787 Dreamliner is a long-haul, wide-body, twin-engine jet developed by Boeing Commercial Airplanes. First entering service in 2011, it was engineered to deliver improved fuel efficiency, enhanced passenger comfort, and better operating economics compared to previous models.

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Composite material: More than half of the Dreamliner’s airframe (by weight) is made from carbon-fiber-reinforced polymer, significantly reducing the aircraft’s weight and improving fuel efficiency.

Efficient engines: Equipped with either Rolls-Royce Trent 1000 or GE GEnx engines, the 787 offers approximately 20% better fuel efficiency than the Boeing 767, the aircraft it was designed to replace.

Long range: The 787-8 variant can fly up to 13,530 kilometers, allowing airlines to operate direct international routes that bypass traditional hub airports.

Air India’s history with the Dreamliner

In October 2012, Air India became the first airline to receive a Boeing 787 Dreamliner assembled at Boeing’s South Carolina facility, marking a departure from the company’s primary production site in Everett, Washington.

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This aircraft was the third Dreamliner delivered to the Indian national carrier, with the first two originating from Everett.

Today, Air India operates a fleet of 787-8 Dreamliners, primarily serving long-haul international destinations including the UK, North America, and the Middle East. The aircraft forms a key part of the airline’s global operations.

A troubled aircraft from the start

The Dreamliner’s development has been marred by setbacks since its inception:

Battery fires: In 2013, the FAA grounded the entire global 787 fleet after lithium-ion battery fires were reported in multiple jets.

Production flaws: From 2019 onward, the 787 program faced serious quality control issues including gaps in fuselage joins, improper shimming, and foreign object debris left inside aircraft.

Delivery halt: Between January 2021 and August 2022, Boeing paused nearly all Dreamliner deliveries amid FAA oversight and internal audits.

Operational issues with Boeing 787 Dreamliner

Jan 8, 2013: JAL 787 suffers fuel leak in Boston; flight cancelled.

Jan 9, 2013: United Airlines finds wiring issue near main battery; US NTSB opens probe.

Jan 11 & 13, 2013: Same JAL aircraft leaks fuel again at Tokyo Narita. Japan’s transport ministry investigates.

Jan 11, 2013: FAA begins comprehensive review of 787 systems.

Jul 12, 2013: Ethiopian Airlines 787 catches fire at London Heathrow; extensive heat damage. Caused by lithium battery in emergency locator transmitter.

Jul 26, 2013: ANA finds wiring damage in 2 aircraft; United reports pinched wire in one.

Aug 14, 2013: Fire extinguisher defect in 3 ANA jets, discharges into wrong engine due to assembly error.

Nov 22, 2013: Boeing warns airlines using GE engines to avoid high-altitude storms due to icing risks.

Jan 21, 2014: Norwegian Air Shuttle 787 suffers fuel leak mid-flight; delay of 19 hours. Issue found after passengers noticed leak. Faulty valve to blame.

Mar 2016: FAA warns of “unrealistic” low airspeed displays, risk of structural failure from abrupt pilot input.

Apr 22, 2016: FAA issues directive after GEnx engine suffers non-restartable failure due to fan ice imbalance.

Jun 18, 2021: British Airways 787-8 nose gear collapses while parked at Heathrow; caused by improperly inserted pin during maintenance.

Mar 11, 2024: LATAM Flight 800 drops suddenly mid-air; 50 injured, 12 hospitalized. Investigation ongoing.

Jun 12, 2025: Air India Flight AI-171 crashes after takeoff from Ahmedabad en route to London.

Whistleblower raised alarm over Boeing safety practices

In early 2024, Boeing engineer and whistleblower Sam Salehpour issued a stark warning about potential safety risks in the company’s production of both the 777 and 787 Dreamliner aircraft.

In interviews with The New York Times and CNN, and in a formal complaint filed with the Federal Aviation Administration (FAA), Salehpour alleged that Boeing had taken dangerous shortcuts in the manufacturing process—practices he claimed could have serious long-term consequences as the aircraft age.

According to Salehpour, Boeing engaged in rushed assembly and improper manufacturing techniques, including faulty drilling on the 787 and the use of misaligned body parts on the 777. He also claimed that engineers were pressured to approve work that had not been properly inspected. His concerns, he says, were met with internal retaliation after he raised them.

One of his most serious allegations involved tiny gaps between fuselage sections on the Dreamliner, which he said were filled improperly. Over time, he warned, these could lead to fatigue cracks, posing a catastrophic risk. Salehpour estimated that more than 400 Boeing 777s and over 1,000 Dreamliners could be affected. “These planes are being flown with a ticking time bomb,” he said.

With inputs from agencies