FAA Orders Mandatory Inspections of Boeing 787 Forward Bulkheads
The Federal Aviation Administration (FAA) has issued an airworthiness directive (AD) requiring visual inspections of the forward bulkheads on all Boeing 787 aircraft registered in the U.S. The directive follows concerns over small gaps in this critical section of the aircraft, which helps maintain pressurization.
Manufacturing Defect and Industry Response
The issue, attributed to a manufacturing defect, has been known within the aviation industry for years. However, until now, the FAA had not mandated inspections. Boeing previously issued a service bulletin in October 2024 advising operators to inspect the affected area, though the manufacturer has maintained that the issue does not pose a safety risk, allowing all impacted aircraft to continue normal operations.
The FAA’s directive applies to 135 Boeing 787-8, 787-9, and 787-10 aircraft currently in service in the U.S. The agency’s document cites “multiple nonconformances, including excessive gaps and pull-up, found during the assembly and installation of the forward pressure bulkhead.”
Potential Structural Integrity Risks
The FAA warns that if these defects are not addressed, they could lead to undetected fatigue cracks that may compromise the aircraft’s primary structure, potentially affecting its long-term structural integrity. The estimated cost to U.S. operators for the inspections is $850 per aircraft, totaling $114,500 for the affected fleet.
While the forward bulkhead issue appears to be minor and relatively easy to address, it adds to Boeing’s ongoing manufacturing challenges. In April 2024, a whistleblower raised concerns that small gaps in the joints connecting different sections of the Boeing 787 could compromise the long-term structural integrity of the airframe.
This latest directive reinforces the FAA’s intensified scrutiny of Boeing’s manufacturing processes, ensuring continued safety oversight of the 787 fleet.
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Sources: AirGuide Business airguide.info, bing.com, aerotime.aero