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Boeing 787 Dreamliner Faces Renewed Scrutiny After AI-171 Crash

Boeing 787 Dreamliner Faces Renewed Scrutiny After AI-171 Crash
The Boeing 787 Dreamliner, the aerospace giant’s flagship wide-body aircraft, has come under intense scrutiny following the tragic crash of Air India Flight 171 near Ahmedabad airport on Thursday. The accident resulted in the deaths of 241 passengers and crew, leaving only a single survivor. This marks the first major fatal incident involving the Dreamliner and has reignited concerns over Boeing’s safety standards and the aircraft’s overall reliability.
Background and Ongoing Safety Concerns
Since its debut in 2011, the 787 Dreamliner had maintained a commendable safety record despite encountering early technical challenges. Notably, the aircraft was temporarily grounded in 2013 after a series of lithium-ion battery fires prompted a comprehensive redesign of its battery system. Although deliveries resumed following these modifications, the Dreamliner has continued to face quality-control challenges. Production was halted from 2021 until March 2023 due to manufacturing irregularities, underscoring persistent issues within Boeing’s supply chain and assembly processes.
In April 2024, the U.S. Federal Aviation Administration (FAA) initiated an investigation after whistleblower and former Boeing engineer Sam Salehpour raised alarms about improperly fastened sections of the 787’s fuselage. These allegations suggested potential structural vulnerabilities that could worsen as the aircraft ages. In response, the FAA ordered reinspections of all 787s currently in production and mandated Boeing to develop comprehensive assessment plans for those already in service.
Context Within Boeing’s Broader Safety Challenges
The AI-171 crash arrives at a particularly sensitive juncture for Boeing, which is still grappling with the fallout from the 737 MAX disasters. The 737 MAX, a model more widely used in India with 63 deliveries over the past decade, was grounded globally between 2019 and 2020 following two fatal crashes linked to a defective flight stabilization system. More recently, in January 2024, the FAA grounded 171 MAX jets after a door plug detached mid-flight on an Alaska Airlines flight, further exposing systemic production and quality control deficiencies within Boeing’s operations.
For Air India, the crash not only threatens its reputation but also casts a shadow over its expansion plans in India’s rapidly growing aviation market. The airline currently operates 27 787-8 Dreamliners, with the last five delivered in 2017, and its subsidiary Vistara has received six larger 787-9 variants between 2020 and 2024. Additionally, Air India has 20 more Dreamliners on order. The incident has also reignited public debate and conspiracy theories surrounding the Dreamliner’s safety, particularly in light of previous battery issues and whistleblower claims.
Industry and Regulatory Response
The aviation and insurance sectors are closely monitoring the repercussions of the AI-171 crash, evaluating its potential impact on Boeing, Air India, and the wider market. Authorities are actively searching for the flight’s black box, while India’s Aircraft Accident Investigation Bureau (AAIB) prepares to lead the official inquiry. The findings of this investigation are expected to influence regulatory policies and public confidence in Boeing’s flagship aircraft.
As the Dreamliner faces its first major crash investigation, Boeing’s capacity to address mounting safety concerns and rebuild trust is once again under intense examination. The company’s response will be critical as regulators, airlines, and passengers demand greater assurance of the aircraft’s safety and reliability.

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