A devastating crash involving an Air India Boeing 787-8 Dreamliner has brought global attention back to serious safety concerns flagged over a year ago. On Thursday, Flight AI171 from Ahmedabad to London crashed shortly after takeoff, killing more than 200 people. While investigations are ongoing, the incident has triggered renewed focus on Boeing’s safety standards, particularly regarding the 787 series.
In 2024, Sam Salehpour, a veteran Boeing engineer, made public allegations of unsafe manufacturing practices at the company. According to his formal complaint to the US Federal Aviation Administration (FAA) and subsequent media interviews, Salehpour claimed that Boeing assembly workers at times physically jumped on fuselage sections to force them into alignment. He said this resulted in dangerously compromised structures that may lead to catastrophic failures after years of use.
Salehpour warned that over 1,000 Dreamliners could be affected by these assembly shortcuts. The structural concern centered around gaps in fuselage joints and the use of excessive force during production—practices he said could lead to premature fatigue in the aircraft’s composite materials. Despite Boeing's assurance at the time that extensive testing showed no immediate flight safety concerns, the FAA launched an investigation that remains open.
The June 2025 crash is the first fatal accident involving a 787 since the model’s commercial debut in 2011. The Directorate General of Civil Aviation (DGCA) is currently leading the probe, with no confirmed connection yet between the crash and Salehpour’s prior warnings. However, the timing has reignited public concern. Boeing issued a statement expressing condolences and support for Air India and the victims' families, while reiterating its commitment to safety.
The crash adds to Boeing’s growing list of safety controversies. Alongside the 787, Salehpour also raised similar concerns about the Boeing 777. Meanwhile, the company has already faced intense scrutiny over its 737 Max line, which was grounded globally between 2019 and 2020 after two deadly crashes. The Max series faced another setback in January 2024 after a door plug blowout incident grounded the Max 9 temporarily.
In addition to FAA restrictions, Boeing has undergone leadership changes and is under criminal investigation by the US Justice Department. These recent events, combined with whistleblower allegations and past manufacturing halts, point to a deeper, systemic issue in Boeing's production and quality control practices. While the final report on the Air India crash is awaited, the legacy of warnings from engineers like Salehpour and the late John Barnett raises urgent questions about the long-term safety of Boeing aircraft and the regulatory oversight meant to ensure passenger safety.
