Boeing engineer-turned-whistleblower, Sam Salehpour, has raised serious concerns about the safety of the aerospace giant's 787 Dreamliner, claiming that assembly flaws could cause the plane to "drop to the ground" midflight unless addressed. Salehpour, who is expected to testify before a U.S. Senate subcommittee, has alleged that tiny nonconforming gaps found in multiple planes during assembly could lead to catastrophic outcomes. Despite Boeing's reassurances that the 787 is safe, Salehpour remains steadfast in his claims, stating that production should be halted while the alleged problems are addressed.

The U.S. Federal Aviation Administration (FAA) is investigating Salehpour's claims, which also extend to Boeing's 777 jets, where he identified engineering problems affecting structural integrity. Salehpour has accused Boeing of taking shortcuts during 787 Dreamliner assembly, leading to excessive stress on major aeroplane joints and embedded drilling debris on over 1,000 planes. Boeing, however, has denied these claims and stated that the company has conducted rigorous engineering examinations under FAA oversight.

In an effort to reassure the public, Boeing conducted a briefing at its Dreamliner manufacturing plant in South Carolina, where top engineers defended the structural integrity of the 787. They stated that extensive testing had been done, and there was no evidence of premature failure in the plane's body. Despite these assurances, Salehpour's allegations have caused a public relations problem for Boeing, which has been under scrutiny following a midflight blowout on a 737 Max plane in January.

Salehpour's attorney, Lisa Banks, has expressed confidence in his allegations, stating that they are based on Boeing's own data and Salehpour's decades of experience as a quality engineer. The FAA has encouraged voluntary reporting in the aviation industry and has pledged to thoroughly investigate all reports. As Salehpour prepares to testify before Congress, the aviation community awaits further developments in this ongoing safety crisis at Boeing.