The Federal Aviation Administration issued a final airworthiness directive requiring repetitive ultrasonic inspections of certain Boeing 787 Dreamliner aircraft after manufacturing errors led to shim gaps exceeding engineering specifications.
The directive applies to 17 U.S.-registered 787-8, 787-9, and 787-10 jets, with an estimated compliance cost of $24,310 per inspection cycle per aircraft. Total first-cycle costs for domestic operators are projected at $413,270, according to the FAA notice published on March 13, 2026.
Boeing attributed the issue to manufacturing errors dating to 2019 and noted it issued a service bulletin in August 2025 outlining inspection procedures. The gaps were identified in the lower side of body splice plates common to the lower outboard wing skins, where high pull-up forces could accelerate fatigue crack formation at fastener holes.
The FAA’s directive mandates repetitive ultrasonic inspections of splice plates, rear spar terminal fittings, lower chords, front spar terminal fittings, and jack pads for cracks, alongside detailed inspections of specific splice plates. Operators must perform on-condition repairs if cracks are detected.
Boeing stated it has been collaborating with airlines, including United Airlines and American Airlines, and asserted that affected aircraft can continue normal operations pending inspections. The company did not disclose potential impacts on delivery schedules or production rates.
