Скачать или смотреть Air India Crash | When Boeing Whistleblower Warned Of A "Catastrophe" | "787 Dreamliner Is Flawed"

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As the devastating crash of Air India Flight 171—a Boeing 787-8 Dreamliner—shakes the nation, chilling past warnings from a Boeing engineer have resurfaced, casting a fresh spotlight on the safety of Dreamliner jets.

Sam Salehpour, a veteran quality engineer at Boeing, had raised serious red flags in 2021 and 2022, accusing the aerospace giant of compromising safety during the production of its 787 Dreamliners. His allegations pointed to systemic issues, including what he described as “faulty engineering” and a dangerous disregard for critical manufacturing tolerances.

At the heart of his concerns was the process of shimming—used to fill microscopic gaps between fuselage sections. While the gaps were often no wider than a human hair, Salehpour warned that such seemingly minor flaws could trigger fatigue cracks over time, especially under the extreme conditions of flight. “Details the size of a human hair can be a matter of life and death at 35,000 feet,” he cautioned.

Even more alarmingly, Salehpour claimed that inspection data from 29 aircraft showed gaps exceeding allowable limits a staggering 98.7% of the time. He alleged that rather than correcting the misalignments properly, workers were instructed to force components into place using excessive pressure.

His concerns didn’t stop with the 787. Salehpour also recounted disturbing practices on the 777 assembly line, saying he saw employees “literally jumping on pieces of the airplane to get them to align.” He dubbed it the “Tarzan effect”—a symbol, he said, of a culture that prioritized speed over safety.

Salehpour formally reported his findings to the Federal Aviation Administration (FAA), which subsequently interviewed him during its ongoing investigation into Boeing's manufacturing standards.

Now, in the wake of a tragic crash involving the very aircraft he warned about, Salehpour’s testimony takes on new urgency—and raises troubling questions about whether enough was done to heed his alarms.
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