The Boeing 787’s composite skin is under the eye now, with the carbon fiber structure deconstructing after improperly joined structural stiffeners fail. Longerons are installed on a wound carbon fibre barrel, frames and longerons are secured to the skin to strengthen the structure, and reinforced by shims. Without shims making a tight fit, damage incurs to the carbon fiber.

The problem has been located on an All Nippon Airways (56), and two Qatar Airways airframes (57 and 58), all of which originate in Everett Washington.

More 787s are expected to turn up with the same problem.

The structural stiffeners are failing in the location of the Alenia Aeronotica-built horizontal stabiliser.

Boeing confirms that the problem is a “straightforward repair that should cause no short-term safety concern.”

Inspections are already underway, and strategic plans for repairs are on the drawing board. A 2010 problem involved the teardown and reinstallation of some Alenia Aeronautica-built horizontal stabilisers which had been assembled without adequate shims.

In George’s Point of View

updated

According to a Reuters article, Boeing is saying publicly that this will not affect production.

It SHOULD affect production.

Boeing needs to slow down and get it right. Thousands of souls will fly in these “things.” Boeing’s got to have it right. Instead of ramping up, slow down production. What good is an ambitious target rate if the planes come out needing SAFOs (Safety Alerts for Operators)?

Too fast reminds me of Airbus.