Air India crash highlights a new problem for Boeing: the Dreamliner

The deadly crash of Air India Flight 171 last week has centered renewed scrutiny on the airplane's manufacturer, Boeing, and this time it's the 787 Dreamliner in investigators' sights. The accident, which killed over 270 people, was the first fatal crash for the Dreamliner since the model began flying in 2011.

Experts had previously raised concerns about safety issues for the Dreamliner, and the crash comes just weeks after Boeing agreed to a multi-billion-dollar payout related to another one of its faulty aircraft, the 737 Max. Now, the Dreamliner's troubles may begin to overshadow the Max's issues.

More problems for Boeing

Worries about the Dreamliner are not entirely new, as the "planes have been the subject of heightened scrutiny after whistleblowers raised concerns about manufacturing and quality issues going back many years," said The New York Times. Despite these concerns, the plane had never been involved in a fatal crash in the 14 years it has been flying, according to the Aviation Safety Network.

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The cause of the Air India crash remains unclear, and "multiple factors, including bird strikes, pilot error, manufacturing defects or inadequate maintenance, can play a role in aviation accidents," said the Times. Determining the cause of the accident could take "months or years." Boeing "stands ready to support the investigation led by India's Aircraft Accident Investigation Bureau," said Boeing President and CEO Kelly Ortberg in a statement.

But this is only the latest in a string of issues for Boeing, which has faced public ire over safety incidents in recent years. Just weeks before the Air India crash, Boeing "agreed to pay $1.1 billion in a deal with the U.S. Department of Justice to avoid prosecution over the two crashes that together killed 346 people" on 737 Max jets, said The Guardian.

Recent problems with the Dreamliner have also drawn attention. American Airlines decided to ground a "new premium-heavy Boeing 787-9 Dreamliner due to serious maintenance problems," the aviation news site Simple Flying reported two days before the Air India crash. Another Dreamliner that was "identical to the one that crashed in India made four emergency landings in less than a month earlier this year," said The Telegraph.

New questions

The Dreamliner debacle "comes at a critical moment for the hobbled American icon, which has been buffeted by a succession of crises in recent years, losing billions of dollars due to plane groundings and production delays," said The Wall Street Journal. The Air India crash will likely "raise fresh questions about Boeing just as it begins to emerge from the fallout of a high-profile incident early last year when a door plug on a recently delivered 737 Max fell off during a flight."

Boeing employees have "observed shortcuts taken by Boeing" during assembly of the Dreamliner, "resulting in drilling debris left in interfaces and deformation of composite material," one Boeing engineer told CBS News. The engineer also claimed to have witnessed issues with other models. While this was the first fatal crash involving the Dreamliner, the plane has been "involved in previous investigations."

The Air India crash was also critically timed for Boeing on the business side, as it occurred "days before the opening of the Paris Air Show, a major aviation expo where Boeing and European rival Airbus will showcase their aircraft and battle for jet orders from airline customers," said The Associated Press. Boeing has already been dealing with significant losses in recent years, having "posted a 2024 loss of $11.8 billion," said CBS, bringing its total losses to over $35 billion since 2019.