Following the tragic Air India plane crash in Ahmedabad, lawyers for Boeing whistleblower Sam Salehpour are demanding the immediate release of a Federal Aviation Administration (FAA) report concerning alleged structural defects in Boeing's 787 and 777 aircraft. The Air India aircraft that crashed shortly after takeoff on June 12, 2025, was a Boeing 787-8 Dreamliner, intensifying concerns about the safety of this aircraft model.
Salehpour, a Boeing quality engineer with over four decades of experience, raised serious concerns in early 2024 about the structural integrity of Boeing's 787 Dreamliner and 777 aeroplanes. He claimed that shortcuts taken during the manufacturing process could compromise the safety and lifespan of the aircraft. Specifically, Salehpour alleged that improper fastening of fuselage sections and the use of excessive force to align parts could lead to premature fatigue in the aircraft's composite materials. He also reported that workers were "jumping on aircraft parts" to force them into proper alignment, and that critical gaps in the fuselage were not being properly filled.
These allegations prompted the FAA to launch an investigation into Boeing in March 2024. According to Salehpour's legal team, the lead FAA investigator informed them in December 2024 that the investigation was complete and expressed appreciation for Salehpour's identification of important safety issues. His lawyers, Debra Katz and Lisa Banks, stated that the investigator assured them the report would be issued imminently and that they understood from his comments that many of Salehpour's concerns had been substantiated. However, nearly six months later, the report has not been released.
In light of the recent Air India crash, Katz and Banks have written to the FAA, urging the agency to immediately publish the report without further delay. They argue that no one can truly understand the risks resulting from Boeing's manufacturing processes until the FAA releases its investigative findings. The lawyers emphasize the need for transparency and accountability to ensure public safety and to address the potential flaws in Boeing's aircraft.
The Air India crash, which claimed the lives of 241 people, has intensified scrutiny of the 787 Dreamliner and Boeing's manufacturing practices. While the cause of the crash is still under investigation by the Directorate General of Civil Aviation (DGCA), the incident has reignited concerns about the structural integrity of the aircraft and the potential impact of manufacturing defects.
Salehpour himself has stated that he raised these issues over three years ago but was ignored and told to "shut up." He claims that shortcuts were employed by Boeing to reduce bottlenecks during the 787 assembly process, placing excessive stress on major airplane joints and embedding drilling debris between key joints on more than 1,000 planes. He believes these errors significantly reduce the lifespan of the aircraft.
The FAA's investigation into Boeing's manufacturing processes and the subsequent report are crucial for determining the extent of the alleged structural defects and their potential impact on the safety of the 787 and 777 aircraft. The immediate release of the report is essential for informing the public, ensuring accountability, and preventing future tragedies.
