The crash of Air India Flight AI-171, a Boeing 787-8 Dreamliner, near Ahmedabad on June 12, 2025, has brought intense scrutiny to the aircraft's design and maintenance. The tragedy, which claimed 274 lives, is now the subject of a complex investigation involving the Directorate General of Civil Aviation (DGCA), the National Transportation Safety Board (NTSB), and the Aircraft Accident Investigation Bureau (AAIB). A key area of focus, according to aviation attorney D. Michael Andrews, involves the potential role of water leaks and the aircraft's redundant systems in the disaster.

Andrews, who represents families of the victims, is exploring product liability claims against Boeing in U.S. federal courts and Montreal Convention claims against Air India in UK courts. He is pursuing a theory centered on water intrusion into the Boeing 787-8's electrical and equipment bay, which houses critical flight computers, including the Full Authority Digital Engine Control (FADEC) and Thrust Control Malfunction Accommodation (TCMA) systems. These systems are responsible for autonomous aircraft control. Andrews points to the presence of water lines and couplings in the area above the equipment bay, noting that these components have a history of leaks in prior 787-8 aircraft. Boeing has issued service bulletins in the past addressing coupling leaks that could allow water to enter computer equipment.

The FAA has also taken note of the risks associated with water leaks in Boeing 787s. In May 2025, the agency issued a directive mandating comprehensive inspections of Boeing 787 Dreamliner aircraft following reports of water leaks that could potentially compromise the safety and integrity of the planes. The inspections are to focus on areas around the aircraft's windows, doors, and other structural joints where seals may have deteriorated or failed. The FAA emphasized the importance of timely compliance to prevent any escalation of damage that could affect flight safety. Earlier concerns, dating back to 2022, highlighted instances of water leaking into a jet's electronics bay. One incident involved water migrating into the forward electronic equipment bay and affecting multiple pieces of electronic equipment. These leaks were attributed to detached or improperly installed "clamshell couplings".

Adding another layer of complexity, the investigation is also exploring the potential for software glitches in the Boeing 787's engine control systems. There are similarities between the AI-171 crash and a 2019 incident involving All Nippon Airways (ANA), where a software flaw in the Boeing 787's engine control systems caused both engines to lose power mid-flight. The systems in question are the Thrust Control Malfunction Accommodation (TCMA) and the Full Authority Digital Engine Control (FADEC). These computer-based systems manage engine power, and if the software incorrectly senses that the plane is on the ground when it is actually in the air, it can automatically reduce engine thrust.

The Boeing 787 relies heavily on electrical systems, with many mechanical components replaced by electrical systems to save weight. While this design improves fuel efficiency, it also increases the aircraft's dependence on a continuous and reliable electrical power supply. To ensure this, Boeing incorporated multiple layers of redundancy, including six electrical generators and a lithium-ion battery backup system. However, a potential single point of failure exists in the software within the generator control units. A software error could result in a total loss of electrical power to the aircraft, even in flight.

The deep integration of systems in the Boeing 787, while intended to enhance efficiency and safety through redundancy, may also create vulnerabilities. The FAA issued guidance in 2020 acknowledging that the 787's design, while physically and logically redundant, could still lead to common-mode failures, data corruption, or unpredictable interactions. This means that even with backup systems in place, a single point of failure, such as a software glitch or water damage affecting multiple systems, could have catastrophic consequences.

As the investigation into the AI-171 crash continues, the focus on potential water leaks, software glitches, and the performance of the aircraft's redundant systems highlights the critical importance of robust design, rigorous maintenance, and continuous monitoring to ensure the safety of modern aircraft.