A recent report submitted to the US Senate has cast a shadow over the tragic crash of Air India Flight 171, a Boeing 787-8 Dreamliner, which occurred on June 12, 2025, in Ahmedabad, India. The crash, which took place shortly after takeoff and claimed the lives of 260 people, is now under scrutiny due to allegations of long-standing technical defects in the aircraft.

The Foundation for Aviation Safety (FAS), a US-based aviation safety group, presented its findings to the US Senate on January 12, 2026. The report alleges that the aircraft involved, registered as VT-ANB, suffered from a multitude of technical problems throughout its 11-year service life with Air India. According to FAS, these issues stemmed from a "wide and confusing" mix of engineering, manufacturing, quality, and maintenance shortcomings.

The alleged problems included electronic and software faults, repeated tripping of circuit breakers, wiring damage, short circuits, loss of electrical power, and overheating of power system components. FAS claims that these issues began on the very first day the aircraft entered service with Air India, February 1, 2014, and persisted throughout its operational history.

One specific incident highlighted in the report was a fire in the P100 primary power panel in January 2022. The P100 panel is a critical power distribution unit that receives power from the left engine and supplies electricity to several aircraft systems. The fire reportedly caused extensive damage, requiring the entire panel to be replaced. In April 2022, the aircraft was allegedly grounded due to faults related to the landing gear indication system, leading to the replacement of multiple components.

FAS's analysis is based on over 2,000 aircraft systems failure reports related to the 787, covering approximately 18% of the global fleet. The organization suggests that these reported failures are just the "tip of the iceberg," indicating a broader issue within the 787 fleet. The report also suggests that similar electrical system failures have been observed in other Air India 787 aircraft, as well as in 787s registered in the US, Canada, and Australia.

The preliminary report released by India's Aircraft Accident Investigation Bureau (AAIB) indicated that the fuel control switches were moved to the "cut-off" position shortly after takeoff. This finding has led to speculation about potential pilot error, a narrative that FAS disputes, comparing it to the early investigations into the Boeing 737 MAX crashes. The AAIB is continuing its investigation, with assistance from US officials.

Boeing has declined to comment on the FAS report, deferring to the AAIB investigation. Air India and the civil aviation ministry have also not responded to requests for comment.

The FAS report raises serious questions about the safety oversight of Boeing 787 aircraft and whether potential systemic issues were downplayed. The US Senate Permanent Subcommittee on Investigations is now reviewing the evidence to assess its implications for airline safety.