March 13, 2026 — Washington, D.C. The U.S. Federal Aviation Administration (FAA) issued a Notice of Proposed Rulemaking (NPRM) proposing Airworthiness Directive AD-2025-01361-T, mandating FAA mandates inspections on Boeing 787 Dreamliners due to shim gap manufacturing defects on certain Boeing 787-8, 787-9, and 787-10 airplanes. The action addresses manufacturing errors causing shim gaps exceeding engineering allowances at lower side-of-body splice plates, combined with excessive preload forces, which could lead to fatigue cracks at fastener holes and compromise wing structure.
The proposal affects approximately 17 U.S.-registered airplanes, as specified in Boeing Alert Requirements Bulletin B787-81205-SB570048 RB, Issue 001, dated Aug. 11, 2025. Operators must conduct repetitive ultrasonic inspections on splice plates, rear/front spar terminal fittings, lower chords, and jack pads, along with detailed inspections on splice plates No. 1 and 2 for cracks. Any detected cracks require repairs per Boeing procedures.
Required Actions and Timeline
Compliance is required per the Boeing bulletin, adjusted to the AD’s effective date. Comments on the NPRM are due by April 27, 2026. The estimated cost is $24,310 per inspection cycle per aircraft (286 labor hours at $85 per hour), totaling about $413,000 for the U.S. fleet, though warranties may cover expenses.
Simple Flying reported on March 14, 2026, that there is no immediate safety risk to flying aircraft, but some may require repairs, potentially impacting fleet availability.
Background and Manufacturing Issues
Boeing issued the related alert bulletin in August 2025 following a shim gap probe. The issue stems from gaps at the lower outboard wing skins’ splice plates, potentially weakening primary wing structure and risking loss of safe flight or landing if undetected. Flight Global noted on March 13, 2026, that this follows 2024 whistleblower concerns over fuselage gaps, which were addressed through fatigue tests, with the current directive limited to specific manufacture dates.
FAA mandates inspections on Boeing 787 Dreamliners due to shim gap manufacturing defects aligns with ongoing scrutiny of Boeing’s production quality. Aero News Journal described it as urgent inspections for fatigue risk on March 16, 2026.
Social Media and Coverage
On X, aviation accounts highlighted the development. @FlyingFreak73 from Aero News Journal linked to their coverage of FAA mandates inspections on Boeing 787 Dreamliners due to shim gap manufacturing defects. @MultibaggAIHQ noted potential repairs and delays, stating, “The FAA issued an urgent directive for mandatory checks on Boeing 787s after discovering shim gap issues in manufacturing, potentially affecting fleet availability and airline schedules. No immediate safety risks to flying aircraft, but some may need repairs.”
@thomaspower4 shared the Flight Global article. No public statement from Boeing as of March 16, 2026; updates expected via boeing.com or the FAA docket.
The fleet remains safe to operate pending inspections, per Boeing’s bulletin.