Boeing 787 Crash

The Boeing 787 Dreamliner, a symbol of modern aviation, was designed to be a game-changer. Constructed with lightweight composite materials and equipped with sophisticated electrical systems, it promised greater fuel efficiency and a new level of passenger comfort. For over a decade, it maintained an impressive safety record with no fatal accidents. However, a recent and tragic event has cast a shadow over this legacy, prompting renewed scrutiny of the celebrated aircraft.

The First Fatal Crash: Air India Flight 171

On June 12, 2025, the aviation world was stunned by the news of the first fatal crash involving a Boeing 787 Dreamliner. Air India Flight AI171, a 787-8 model, was en route from Ahmedabad, India, to London with 242 people on board. Just five minutes after takeoff, the aircraft crashed into a residential area in Meghaninagar, near the airport.

The crash of flight AI171 resulted in the tragic loss of 241 lives, with only a single passenger surviving. The aircraft, which was approximately 11.5 years old, had accumulated over 41,000 flight hours. Preliminary reports and security footage from the takeoff have become a focal point for investigators. Experts have noted that the plane had only reached an altitude of about 625 feet. Video analysis suggests that the landing gear was still down and, crucially, the wing flaps may not have been extended, which is essential for generating lift during takeoff. While it is too early to determine the exact cause, these observations have led to questions about whether the incident was a result of mechanical failure or pilot error.

The investigation is being led by India's Aircraft Accident Investigation Bureau, with support from the U.S. National Transportation Safety Board and Boeing. In the wake of the disaster, Indian authorities began inspecting the entire Air India fleet of Boeing 787s. The crash has undoubtedly put the Dreamliner's safety record under a microscope.

A History of Technical Challenges

While the Ahmedabad crash was the first fatal incident, the Boeing 787 has faced other significant safety concerns and technical issues throughout its operational history.

The 2013 Battery Fires and Grounding

A major test for the Dreamliner came in January 2013. A fire broke out in a lithium-ion battery on a Japan Airlines 787 parked at Boston's Logan International Airport. Days later, another 787, operated by All Nippon Airways, made an emergency landing in Japan due to a smoldering battery. These incidents led the U.S. Federal Aviation Administration (FAA) and other global aviation authorities to ground the entire worldwide fleet of 787s for nearly three weeks.

The cause was traced to a phenomenon known as "thermal runaway" in the powerful lithium-ion batteries used in the aircraft's electrical systems. Boeing was forced to re-engineer the battery system with improved insulation and a new steel containment box to prevent a recurrence. The fleet was cleared to fly again in April 2013 after the revised design was approved.

LATAM Airlines Sudden Plunge

More recently, in March 2024, a LATAM Airlines Boeing 787-9 flying from Sydney, Australia, to Auckland, New Zealand, experienced a sudden, terrifying plunge that injured 50 people. A preliminary investigation suggested that an accidental movement of a pilot's seat in the cockpit may have pushed the controls, causing the rapid loss of altitude. In response, Boeing issued a directive to airlines to inspect the switches on pilots' seats.

A String of Other Incidents

Over the years, various airlines have reported a range of issues with the 787. Between 2015 and 2024, Air India alone reported 32 incidents involving its 787 fleet, including engine shutdowns, flight control glitches, smoke in the cabin, cracked windshields, and hydraulic leaks. In one instance in December 2024, an Air India 787 reported a hydraulic leak in its nose gear upon landing in Birmingham, UK.

Just days after the tragic crash in Ahmedabad, another Air India 787-8 had to turn back to Hong Kong shortly after takeoff due to a suspected technical issue on June 16, 2025. An Ethiopian Airlines 787 also caught fire at London's Heathrow Airport in July 2013, though there were no passengers on board at the time. The fire was traced to a faulty emergency locator transmitter.

The Dreamliner's Legacy in Question

The Boeing 787 was a revolutionary aircraft, the first to have an airframe constructed primarily of composite materials. It also features more extensive electrical systems than its predecessors. While these innovations brought about significant gains in fuel efficiency, they also introduced new complexities and potential vulnerabilities. A whistleblower in 2024, who was a Boeing quality engineer, raised concerns about shortcuts in the assembly process of the 787, alleging that drilling debris was left in interfaces and that there was deformation of composite materials.

Until the recent crash, the 787 had a stellar safety record, with no hull losses or fatalities in over a decade of service. It has been a popular and profitable aircraft for Boeing, with over 2,100 orders and more than 1,100 delivered to airlines worldwide.