FAA mandates Boeing 787 inspections for structural fatigue cracks

The Federal Aviation Administration (FAA) has issued a final airworthiness directive requiring inspections of certain Boeing 787 Dreamliner aircraft to check for potential fatigue cracks. The directive affects 17 aircraft operating in the United States and 77 worldwide, out of a global fleet of more than 1,100 planes.

The issue stems from manufacturing discrepancies where “shim gaps”—spaces filled during assembly—exceeded engineering specifications. This condition can create excessive loads during assembly, potentially leading to fatigue cracks around fastener holes in the structural plates that connect the wing to the fuselage.

Boeing identified the concern during an investigation and stated that the issue has since been corrected in current production. The FAA mandate requires operators to use methods such as ultrasonic evaluations and detailed visual inspections. If cracks or anomalies are detected, repairs must be completed before the aircraft can continue service.