Boeing engineer says there are issues in more than 400 777s and 1,000 787s|markjhandel|CC BY 2.0

The Federal Aviation Administration (FAA) is investigating allegations made by Boeing engineer Sam Salehpour that sections of the 787 Dreamliner’s fuselage are improperly fastened and could break apart mid-flight after numerous trips.

Salehpour alleges that Boeing took shortcuts in the manufacturing process of its widebody jet. He says there are issues with more than 400 models of 777s and 1,000 models of 787s. 

Boeing has refuted the assertions, insisting that the structural integrity of the 787 Dreamliner is sound.

The FAA investigation into Salehpour’s claims adds to Boeing’s safety crisis ignited by a 737 Max 9 blowout earlier this year. 

The authority is already investigating a separate incident involving a Southwest Airlines Boeing 737-800, where an engine cowling (metal cover) fell off during takeoff.

Silver lining
Boeing’s commercial jet orders surged in March, with American Airlines placing an order for 85 Boeing 737 Max 10s, despite it lacking FAA approval for passenger flights.

Alongside the Max orders, Boeing also received orders for 28 widebody 777 jets.