The Federal Aviation Administration (FAA) is launching an investigation into claims made by a Boeing engineer that assembly defects in the company's 787 Dreamliner raise safety concerns. In a letter sent by Sam Salehpour's lawyers to the FAA in January, the quality engineer at Boeing alleged that shortcuts were taken during the assembly process, leading to drilling debris left in interfaces and deformation of the composite material. Salehpour also mentioned issues with the assembly process of the 777 aircraft.

The New York Times initially reported on the alleged problems with the Dreamliner, sparking further scrutiny into the matter. Salehpour's attorney, Debra Katz, stated in the letter that her client had raised concerns to Boeing management regarding these defects, but they were allegedly dismissed and ignored.

Boeing, however, strongly denied the allegations and released a detailed defense of the aircraft. The company stated that rigorous engineering examinations had been conducted under FAA oversight, and they were fully confident in the structural integrity, quality, and long-term safety of the 787 Dreamliner.

To address any potential safety issues, Boeing revealed that it had slowed down production in 2021 and 2022, and halted deliveries for almost two years after employees identified concerns with the plane. They reassured the public that comprehensive Boeing and FAA analysis confirmed there were no immediate safety concerns for the in-service fleet.

Salehpour's claims are set to be heard by a Senate Homeland Security and Governmental Affairs subcommittee later this month, further highlighting the seriousness of the matter.

In response to the allegations, the FAA emphasized the importance of voluntary reporting without fear of reprisal in ensuring aviation safety. They assured that all reports are thoroughly investigated.

The 787 Dreamliner has been a source of trouble for Boeing, as the company continues to deal with the aftermath of an emergency on an Alaska Airlines flight involving a panel on a 737 Max plane that blew out mid-flight. These incidents have caused production delays and reduced aircraft deliveries to carriers like United Airlines and Southwest Airlines.

As the investigation unfolds, both Boeing and the FAA are committed to addressing any potential safety concerns and maintaining the integrity and longevity of the Dreamliner fleet.