FAA Orders Repairs on Boeing 787s Over Potential Wing Cracks

The Federal Aviation Administration (FAA) has issued an Airworthiness Directive requiring repetitive inspections on certain Boeing 787 aircraft due to potential wing cracks caused by factory flaws.

The directive affects 77 planes worldwide, including 17 registered in the US, and is aimed at detecting fatigue cracks in the primary structural area of the wing. The FAA's move comes after Boeing identified the problem in 2019 while reviewing an outdated method for measuring shims.

The issue arises from excessive preload forces on body splice plates, which can initiate fatigue cracks at fastener holes. If left undetected, these cracks can weaken the primary wing structure and potentially lead to loss of flight capability.

The inspections will be conducted using ultrasonic technology and detailed visual examinations, with follow-up actions required if damage is found. The estimated cost of the inspections ranges from $24,310 to $413,270 per cycle, depending on the number of aircraft affected.