Lufthansa 787 Deliveries Delayed Due to Business Class Seat Approval

Lufthansa 787 Deliveries Delayed Amid Business Class Seat Certification Issues

Certification Challenges Stall Dreamliner Deliveries

Frankfurt—Lufthansa is encountering significant delays in the delivery of its Boeing 787 Dreamliners due to unresolved certification issues surrounding its new Allegris business class seats. Approximately 15 aircraft, intended to showcase the airline’s latest premium cabin design, remain grounded in storage facilities across the United States, including locations near New York’s JFK Airport. The Federal Aviation Administration (FAA) has yet to approve the business class seats, manufactured by Collins Aerospace, despite their installation on the aircraft. This lack of certification has prevented Lufthansa from taking delivery of the planes, leaving the airline’s fleet expansion plans in uncertainty for several months.

The Allegris concept, introduced in 2024, aims to revolutionize Lufthansa’s onboard experience, particularly in business class, by offering all-aisle access seating. While the first Allegris-equipped aircraft, an Airbus A350-900 fitted with seats from Thompson Aero, experienced delays due to supply chain disruptions and incomplete first-class installations, the 787 Dreamliners require separate certification because of differences in cabin configuration and safety standards. Although recent testing of the seats on the Dreamliner fleet has concluded, the FAA continues to evaluate the results. At a December 2024 event, a Lufthansa executive acknowledged the possibility that the seats might ultimately fail to receive approval, casting doubt on the airline’s ambitious fleet renewal strategy.

Broader Impact on Lufthansa’s Modernization Efforts

The certification delays affecting the 787 program compound existing challenges within Lufthansa’s broader modernization initiatives. The airline has already faced a six-year postponement in Boeing 777X deliveries and encountered setbacks in the Airbus A350 rollout linked to Allegris-related complications. With the 787s now also grounded, Lufthansa confronts a significant capacity shortfall amid intensifying competition. Rival carriers such as ANA and Avianca have successfully introduced their new 787 business class products, potentially diminishing Lufthansa’s competitive advantage.

These certification issues occur against the backdrop of wider industry difficulties. Both Boeing and Airbus have struggled to meet delivery targets, delivering only 359 aircraft out of a projected 1,430 in the first four months of the year. This industry-wide slowdown further pressures Lufthansa as it seeks to modernize its long-haul fleet.

In response to the impasse, Lufthansa has considered operating some Dreamliners with only economy and premium economy cabins, leaving the business class section empty. While legally permissible, this solution is far from ideal and underscores the operational challenges posed by the certification delay.

Engineering Complexities Within the Lufthansa Group

The ripple effects of the Allegris certification issues extend beyond Lufthansa’s 787 program. SWISS, a member of the Lufthansa Group, is also introducing Allegris cabins on its Airbus A330 fleet. The airline has reportedly installed 1.5-ton counterweights to compensate for the heavier first-class section, highlighting the engineering complexities associated with the new product line.

Despite these setbacks, Lufthansa executives remain cautiously optimistic. The airline aims to commence 787 deliveries by summer 2025 and have the aircraft operational before the end of the year. However, until the FAA grants certification for the business class seats, the timeline remains uncertain, and Lufthansa’s vision for a redefined onboard experience remains on hold.