Boeing has asserted that its extensive inspections of in-service 787 Dreamliner jets have revealed no signs of fatigue cracks, countering recent allegations by a company whistleblower. The statement comes ahead of a U.S. Senate hearing scheduled for Wednesday, where Boeing’s safety culture will be under scrutiny.
The whistleblower, Boeing quality engineer Sam Salehpour, has claimed that the aerospace giant dismissed safety concerns regarding the assembly processes of its 787 and 777 aircraft. Salehpour alleges that inadequate use of shims—thin pieces of material used to fill small gaps in manufacturing—could lead to premature fatigue failure in certain areas of the 787 Dreamliner over time.
These claims are currently under investigation by the U.S. Federal Aviation Administration (FAA). Salehpour is expected to testify at the upcoming Senate hearing, bringing attention to his observations, which reportedly include witnessing workers forcibly aligning aircraft components.
In response, senior Boeing officials addressed the allegations during a call with reporters on Monday. Steve Chisholm, Boeing’s chief engineer of mechanical and structural engineering, stated, “All these results have been shared with the FAA,” emphasizing that inspections of nearly 700 in-service Dreamliners undergoing heavy maintenance after six and twelve years showed zero findings of airframe fatigue.
Lisa Fahl, vice president of Boeing Commercial Airplanes airplane programs engineering, refuted the reports of improper assembly practices, stating that such methods are “not part of our process.” She noted that the 787’s manufacturing specifications allow for a gap allowance within five-thousandths of an inch over a five-inch area—roughly the thickness of a human hair.
Boeing has faced previous challenges with the 787 program. Deliveries of the widebody jet were halted for over a year until August 2022 as the FAA examined quality control issues and manufacturing flaws. In 2021, the company acknowledged that some 787 aircraft had improperly sized shims and areas not meeting skin-flatness specifications.
Debra Katz, attorney for Salehpour, expressed skepticism regarding Boeing’s assurances. “Any data provided by Boeing should be validated by independent experts and the FAA before it is taken at face value,” she stated, adding that her client had sought access to data addressing his safety concerns for years.
Boeing’s latest defense of its 787 program underscores the ongoing tension between the company and regulators, as well as internal challenges related to safety culture and quality assurance. The outcome of the Senate hearing may have significant implications for the manufacturer’s reputation and operations moving forward.
Reference(s):
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