FAA Cracks Down on Boeing 787 Manufacturing Flaws with Inspections
Published Date: 3/13/2026
Proposed Rule
Summary
The FAA wants to make sure certain Boeing 787 airplanes stay safe by checking for cracks caused by manufacturing issues. They’re proposing regular inspections and fixes if needed to prevent problems. Airlines and maintenance teams should comment by April 27, 2026, and be ready for possible inspection costs and schedules.
Analyzed Economic Effects
2 provisions identified: 0 benefits, 2 costs, 0 mixed.
Mandatory Inspections and Repairs for 787s
The FAA proposes to require repetitive ultrasonic (UT) and detailed (DET) inspections for certain Boeing Model 787-8, 787-9, and 787-10 airplanes, and applicable on-condition repairs if cracks are found. The required procedures and compliance times reference Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated August 11, 2025.
Estimated Compliance Costs and Fleet Size
The FAA estimates this proposed AD would affect 17 airplanes of U.S. registry. The FAA estimates up to 286 work hours × $85 per hour = $24,310 per airplane per inspection cycle, and up to $413,270 total for U.S. operators per inspection cycle; the agency has no definitive data for on-condition repair costs and notes some or all costs may be covered under warranty.
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