The Air India Flight AI171 crash near Ahmedabad on Thursday, June 12, 2025, marks a grim milestone as the first 'hull event' for the Boeing 787 Dreamliner. The aircraft, a Boeing 787-8, crashed shortly after takeoff from Sardar Vallabhbhai Patel International Airport, killing 241 of the 242 people on board. While this is the first fatal crash for the 787, the Dreamliner has been plagued with various problems since its debut in 2011.
Flight AI171, bound for London's Gatwick Airport, crashed into a residential area in Meghani Nagar, just outside the Ahmedabad airport. The aircraft, registered as VT-ANB, was delivered to Air India in January 2014, making it approximately 11.5 years old. The flight had 230 passengers and 12 crew members. One passenger, a British national, survived the crash and is currently receiving treatment in a local hospital.
The crash prompted immediate responses from aviation authorities and the manufacturer. India's Aircraft Accident Investigation Bureau is leading the investigation, with assistance from the U.S. National Transportation Safety Board (NTSB) and Britain's Air Accidents Investigation Branch. Boeing has also offered its support to Air India.
The 787 Dreamliner was introduced in 2011 and Boeing calls it the "best-selling passenger widebody of all time," carrying over a billion passengers since its introduction. The aircraft was designed for long-haul routes. There are over 1,100 Dreamliners in service worldwide.
Despite its generally strong safety record, the 787 Dreamliner has faced scrutiny and a series of operational and manufacturing issues throughout its service life.
Early Issues: In 2013, the entire global 787 fleet was temporarily grounded due to overheating lithium-ion batteries. This led to design changes to better contain the risk of thermal runaway. In July 2013, an empty Ethiopian Airlines 787 caught fire on the ground at Heathrow Airport in London due to a short circuit in an Emergency Locator Transmitter.
Air India's Dreamliner Troubles: Between 2015 and 2024, Air India's 787 flights reported 32 incidents including engine shutdowns, flight control glitches, smoke in the cabin, loss of communication, cracked windshields, cabin pressure issues, turbulence, altitude drops, slat malfunction, tire bursts and hydraulic leaks. In March 2024, a LATAM Airlines 787 experienced a sudden mid-flight drop from Sydney to Auckland, injuring at least 50 people.
Whistleblower Allegations: In April 2024, Boeing engineer Sam Salehpour alleged that Boeing took shortcuts during the 777 and 787 Dreamliner assembly, leading to drilling debris left in interfaces and deformation of composite material. The FAA investigated these claims.
Pilot Concerns and Operational Restrictions: There were reports that Boeing advised Air India to avoid flying Dreamliners near high-level thunderstorms due to icing risks on the engines, leading to the withdrawal of the aircraft from the Delhi-Tokyo route.
The Air India crash is the first hull loss of a 787. Aviation experts suggest that the investigation will focus on several factors, including the actions of the pilots, the airline's maintenance procedures, and potential manufacturing defects related to Boeing. The crash has ignited safety concerns and questions about the reliability of the 787 Dreamliner, especially given Boeing's recent history of safety-related issues with its 737 Max aircraft.
