Boeing Launches $1 Billion South Carolina Expansion as 787 Demand Soars

Boeing has broken ground on a $1 billion expansion of its North Charleston, South Carolina facility, marking one of the largest aerospace manufacturing investments in the state’s history. The move comes as global airlines continue to place record orders for the company’s 787 Dreamliner, fueling unprecedented demand for the fuel-efficient widebody jet.

The expansion will significantly enhance Boeing’s 787 production capabilities at the site, which has served as the sole final assembly line for the Dreamliner since 2020. The company plans to raise output from about seven aircraft per month to ten by 2026, ensuring it can meet the growing backlog of nearly 1,000 unfilled orders.

Record Demand for the 787 Dreamliner

Boeing’s decision to expand in South Carolina follows surging global demand for the 787 Dreamliner family. The program has already logged more than 2,250 total orders from 90 customers worldwide — making it the best-selling widebody jet in history. Over 300 new orders were placed in 2025 alone, pushing the backlog to its highest level in over a decade.

Recent major orders include a record-breaking 130-jet deal from Qatar Airways, Boeing’s largest single order for South Carolina-built aircraft, alongside substantial purchases by United Airlines, American Airlines, and leasing companies such as Avolon. These commitments reflect airlines’ growing focus on fuel efficiency, lower carbon emissions, and long-haul profitability.

Massive Infrastructure Expansion

The $1 billion investment will transform Boeing’s North Charleston site with a new 1.2-million-square-foot final assembly building, a parts preparation facility, a vertical fin paint shop, and additional flight line capacity. The company will also expand its Interiors Responsibility Center, where much of the Dreamliner’s cabin components are manufactured.

Construction will involve over 2,500 workers contributing an estimated 6.2 million labor hours through completion. The project, managed by HITT Contracting and BE&K Building Group, reflects Boeing’s long-term confidence in both the Dreamliner program and South Carolina’s growing role in U.S. aerospace manufacturing.

Economic Boost and Job Creation

Boeing expects to create more than 1,000 new jobs over the next five years as part of the expansion, adding to its existing 8,200-employee workforce in South Carolina. The project is expected to inject billions into the local economy through new supply chain contracts, construction activity, and support services.

Governor Henry McMaster hailed the investment as “a tremendous vote of confidence in our state’s people and business climate,” while Senator Lindsey Graham called it “the ultimate vote of confidence in South Carolina’s workforce.” The expansion cements the state’s growing status as one of America’s leading aerospace hubs.

A Market Poised for Growth

According to Boeing’s 2025 Commercial Market Outlook, airlines will need more than 7,800 new widebody aircraft over the next 20 years, driven by rising long-haul travel and fleet modernization. “We continue to see strong demand for the 787 Dreamliner family and its market-leading efficiency and versatility,” said Stephanie Pope, president and CEO of Boeing Commercial Airplanes. “This investment ensures we’re ready to meet our customers’ needs well into the future.”

Dreamliner deliveries have risen 42% this year, with 28 jets handed over through September 2025, underscoring Boeing’s improving production stability. The company expects the new facilities to be operational by 2026, supporting its target of producing ten 787s per month by 2027.

In 2025, Boeing received more than 300 new orders for its 787 Dreamliner family, bringing the total number of 787 orders to over 2,270 from 90 customers worldwide. This surge in demand reflects the aircraft’s continued appeal for long-haul operations, thanks to its fuel efficiency, passenger comfort, and operational versatility.

Notable deals this year include Thai Airways’ order for 45 787s with options for 35 more, Uzbekistan Airways’ firm order for eight additional jets, and Air Astana’s commitment for up to 15 787-9s—the largest in the airline’s history. Boeing’s South Carolina facility, the sole production site for the 787 since 2020, is planning to ramp up to a production rate of 10 aircraft per month by 2026. With nearly 1,000 aircraft in backlog, the 787 remains the best-selling widebody jet in aviation history, positioning Boeing to meet the growing global demand for efficient long-haul travel.

Strategic and Industry Implications

Boeing’s expansion strengthens the United States’ position as a global leader in aerospace manufacturing and reinforces Boeing’s competitiveness in the widebody market against Airbus’s A350. The 787’s lightweight composite design, advanced aerodynamics, and efficient engines continue to attract airlines seeking sustainable, long-range solutions.

The North Charleston project also enhances Boeing’s geographic diversification, complementing its Washington state operations and reducing production risk. Once complete, the expanded site will stand as one of the world’s most advanced aircraft manufacturing complexes.

With the groundbreaking now complete, Boeing’s South Carolina expansion positions the company to capitalize on the global rebound in long-haul air travel and ongoing fleet renewal cycles. Backed by a near-record order book and growing political and economic support, the project marks a defining moment for both Boeing and South Carolina’s aerospace industry — securing the future of U.S. widebody aircraft production for decades to come.

Sources: AirGuide Business airguide.info, bing.com, boeing.com, yahoo.com