FAA Orders Boeing Inspect 787 Aircraft Over Potential Manufacturing Defects
The Federal Aviation Administration (FAA) has ordered Boeing to inspect its 787 aircraft after finding potential manufacturing defects. The issue is related to excessive preload forces at the lower side of body splice plates, which could lead to fatigue cracks and weaken primary wing structure.
The FAA issued an Airworthiness Directive on August 27, 2026, effective October 1, 2026, covering 17 US-registry Boeing 787-8, 787-9, and 787-10 airplanes. The directive requires repeated inspections of the splice plates, with estimated costs totaling $413,270 across the entire US fleet.
American Airlines objected to the FAA's decision to use an equation-based inspection interval, arguing that it would place a burden on their internal tracking system. However, the FAA rejected this claim, stating that the simplified version American asked for 'would therefore be more burdensome for operators.'