On June 13, 2025, an Air India Boeing 787 Dreamliner crashed in Ahmedabad, killing at least 270 people. The plane went down just 30 seconds after take-off, with the cause still unknown. Investigators have recovered the flight recorders and are working to determine what happened. The crash has raised pressing questions about the aircraft model, previously lauded for its safety and performance.
Before the crash, the 787 Dreamliner had enjoyed a stellar safety record. Since entering service nearly 15 years ago, it has logged over a billion passenger journeys without a single fatal crash. With more than 1,100 in service globally, the Dreamliner was one of Boeing’s most widely used long-haul jets. However, its reputation is now under scrutiny.
The Dreamliner’s origins trace back to the early 2000s when rising fuel prices and the aftermath of 9/11 pushed Boeing to prioritize efficiency over speed. The company abandoned its earlier Sonic Cruiser concept and developed the 787 as a lightweight, fuel-efficient jet using composite materials and advanced technology to support long-haul, direct routes.
Dreamliner’s Innovation Outshone Airbus, But Production Flaws and Safety Setbacks Clouded Success
Boeing’s move contrasted sharply with Airbus, which pursued the giant A380 superjumbo focused on hub-to-hub travel. The Dreamliner, by enabling point-to-point flights between smaller cities, proved the more sustainable vision. With fuel efficiency and reduced noise, the 787 quickly became a favorite among airlines seeking flexibility and cost savings.
Despite the aircraft’s success, its early years weren’t without issues. In 2013, lithium-ion battery fires grounded the entire global fleet. Although Boeing resolved those technical problems, the incident revealed vulnerabilities in the aircraft’s cutting-edge systems and prompted more rigorous oversight and redesign efforts from regulators.
Air India Dreamliner Crash Kills 270, Casting New Doubt on Boeing’s Safety Record and Corporate CultureFrom 2019 onward, Boeing uncovered serious manufacturing flaws, particularly in the way fuselage sections fit together. Quality issues slowed production and halted deliveries multiple times between 2021 and 2023. The problems were traced largely to a second production line in South Carolina, which had been set up to lower costs and limit union influence.
Whistleblowers Warn of Boeing’s Safety Shortcuts Amid Mounting Crashes and Industry Scrutiny
Multiple whistleblowers, including the late John Barnett and Cynthia Kitchens, accused Boeing of sacrificing safety for speed. They alleged that defective parts were deliberately used, and that poor-quality control measures allowed hidden flaws into operational jets. Investigations by the FAA confirmed some of these issues, including missing parts and metal debris in wiring areas.
In 2024, another Boeing employee, Sam Salehpour, told U.S. lawmakers that shortcuts in assembly had compromised the structural integrity of over 1,000 Dreamliners. He warned of fatigue failures in fuselage joints, which could lead to catastrophic results. Boeing rejected the claims, stating that rigorous FAA-reviewed analyses had deemed the aircraft structurally sound.
The Air India crash comes at a time when Boeing’s corporate culture and safety standards are already under fire due to earlier incidents with its 737 Max jets. While new leadership claims to be reforming internal systems, many industry experts question whether past mistakes have permanently undermined the company’s credibility and product integrity.
While the investigation into the Air India crash continues, many aviation experts remain confident in the Dreamliner’s overall safety. Some, like analyst Richard Aboulafia, argue that any critical design flaw would have surfaced by now, given the aircraft’s long operational history. Nonetheless, the tragedy underscores the urgent need for full transparency, accountability, and thorough investigation.
