Boeing has temporarily halted flight tests of its 777X jetliner after the company discovered significant damage to a critical structural component, raising concerns over potential delays in the aircraft's already prolonged certification timeline. The issue, which was identified during routine maintenance, affects a crucial part of the engine mount that connects the massive General Electric Co. engines to the aircraft's wings.
The discovery was made on a 777-9, the first model in Boeing's 777X family, which has been under development for several years. Boeing's team is currently replacing the damaged component and conducting inspections across its test fleet, which consists of four aircraft. As a precautionary measure, the company has grounded all 777-9 test planes until further notice, though no additional flight tests were scheduled for these jets in the immediate term.
"Our team is replacing the part and capturing any learnings from the component and will resume flight testing when ready," Boeing stated, emphasizing that the safety and reliability of its aircraft remain paramount. The company has informed the Federal Aviation Administration (FAA) and its customers, who have placed orders for 481 of the 777X jets, according to Boeing's website.
The damaged part, known as a thrust link, plays a crucial role in attaching the GE9X engines-the largest and most powerful commercial jet engines ever built-to the aircraft. The component "didn't perform as designed," Boeing acknowledged in its statement. The discovery is particularly concerning given that the 777X program has already faced multiple delays, pushing its certification and delivery timeline to 2025, a full five years behind the original schedule.
This latest setback follows a series of challenges for Boeing, including a midair blowout on another of its jets earlier this year, which highlighted ongoing concerns about the company's manufacturing processes and safety standards. The 777X, a new generation of Boeing's successful 777 series, is intended to be a cornerstone of the company's future in the wide-body aircraft market, competing against Airbus's A350.
Ken Herbert, an analyst with RBC Capital, warned that the grounding could further delay the 777X's certification, potentially pushing deliveries into 2026. "The grounding could push 777X delivery expectations to the right, and potentially into 2026," Herbert told clients in a note on Monday. He added that the 777X program would likely face a "prolonged approval period" due to the ongoing inspections and potential redesigns of the affected components.
The Federal Aviation Administration (FAA) has been closely monitoring the 777X's development, particularly after the delays and safety issues that have plagued Boeing in recent years. The company only began flight tests with the FAA on board in July, marking a significant milestone in the certification process. However, the discovery of the damaged engine mount has now cast a shadow over the program's progress.
GE Aerospace, the manufacturer of the GE9X engines, has stated that the issue does not stem from the engines themselves, which remain unaffected. "There is no issue with the GE9X turbofan," a GE Aerospace spokesperson confirmed, reinforcing that the problem lies within the custom-designed engine mount specific to the 777-9 model.
The 777X program is critical for Boeing as it seeks to restore confidence in its wide-body aircraft offerings following the 737 Max crisis, which severely damaged the company's reputation. The 777X, with its cutting-edge technology and improved fuel efficiency, is designed to offer airlines a long-range, high-capacity aircraft capable of meeting the demands of international travel in the post-pandemic era.
Despite these aspirations, the repeated delays and technical issues have frustrated both customers and industry observers. Boeing's announcement of the latest setback has led to renewed speculation about the viability of the 777X's delivery schedule, with some industry experts predicting further delays if additional issues are uncovered during the ongoing inspections.
