The 787 was designed to be the first production airliner with the fuselage comprising one-piece composite barrel sections instead of the multiple aluminum sheets and some 50,000 fasteners used on existing aircraft. Spirit AeroSystems has been manufacturing the forward fuselage structure for the 787 Dreamliner since the aircraft began production in 2007. Originally published November 10, 2008 at 12:00 am. They were delivered to Global Aeronautica in Charleston, South Carolina, on January 15. On January 12, 2007, the first major assemblies, forward fuselage, centre wing, and centre wheel well built by FHI and KHI were shipped on a Boeing 747 400 LCF from Nagoya, Japan. Elsewhere, Vought Aircraft Industries Inc. (Dallas, Texas) reports that its North Charleston, S.C.-based 787 production facility delivered the first shipset of rear fuselage sections in April. Boeing confirmed to The Air Current that it has “identified two distinct manufacturing issues in the join of certain 787 aft body fuselage sections, which, in combination, result in a condition that does not meet our design standards.” This approach represents years of research and development by Boeing into the latest manufacturing processes. Few composite structures made with AFP have come close to the size of even one 787 fuselage section. Boeing Co. found “two distinct manufacturing issues” affecting the fuselage of eight 787 Dreamliner jets and said the planes must be removed from service for repair. Crucially, Boeing has extensive manufacturing data on the shims, but little on the quality of the composite skin surface issue, which is now driving the FAA toward recommending an examination of potentially the entire 787 fleet, which numbers nearly 1,000 since the first delivery in 2011. With that issue and the stabilizer gap, any variation that is greater than 0.005 inch — about the thickness of a human hair — is beyond the maximum allowed. Boeing has been mooting consolidating 787 production in Charleston , removing the Everett FAL from the program. The heavy machinery and engineering company will begin construction in 2014 on land adjacent to its existing facilities in Yatomi, Aichi Prefecture, and plans to start production as early as in 2015. (Seattle Times) Photos of the 787 Fuselage Gaps Westenskow points, tracing the aesthetically pleasing curve. Boeing 787 Dreamliner nose section takes shape in the factory. EVERETT, Wash. (AP) — Boeing Co. says the stress tests for its new 787 jetliner's wing and fuselage went as planned. With the 787 program, Boeing is now globally outsourcing approximately 70% of content, compared to 50% previously. Article content. AFP, even as the 787 program dawned, had been used for many years, so it was not new to composites manufacturing. What was new, with the 787, was the scale of the application. All Boeing’s Dreamliner fuselage fabrication and joining is conducted at Charleston, although they may then go on to final assembly at either the nearby FAL or its other factory in Everett. The flaws were found in the joint of sections toward the rear of the wide-body aircraft, the company said by email Friday. The CSRT is pleased to submit to you our report on the Boeing 787–8 Design, Certification, and Manufacturing Boeing Co. found two “distinct manufacturing issues” in the fuselage of 787 Dreamliner jets and has told airlines operating eight affected planes to … At one of the newest Boeing manufacturing locations, a new machining technology will be used to process a new choice of material within a new aircraft. The technology was developed by Mag. Section 43 is connected in Charleston, S.C., with mid fuselage sections 46 and 44 that are manufactured by Alenia in Italy. An example is the Boeing 787 Dreamliner jet, which is made almost entirely of plastic composite, replacing many traditionally aluminium components. Boeing said in August airlines operating its 787 Dreamliners had removed eight jets from service as a result of two distinct manufacturing issues in fuselage sections. Kawasaki Heavy Industries Ltd. will construct a new factory to produce larger fuselages for the Boeing 787 Dreamliner aircraft, its officials said Tuesday. Commercial Airplanes (Boeing) tasked the Boeing 787‒8 Critical Systems Review Team (CSRT) to perform a comprehensive review of the Boeing 787‒8 critical systems, including the airplane’s design, manufacture, and assembly. Produced by Mitsubishi Heavy Industries in Japan, its carbon-fiber–aluminum hybrid structure is as mean as it is lean. Gaps in fuselage joins could lead to premature aging. The fuselage is made entirely of plastic composite, reducing the number of fasteners required by 80% compared with … The strikingly svelte 787 wing, displayed overhead in the jig that mates it to the fuselage, looks like a gallery exhibit. Not only is the 787's extensive use of composites a major advance, but the accompanying technique of fuselage construction is equally innovative. Photo: Boeing Newsroom ... “Grounding airplanes for manufacturing flaws is unprecedented and unbelievable.” According to reports, multiple FAA investigations into the 787 Dreamliner are now a single, larger, investigation. Boeing disclosed a new manufacturing quality issue, this time with assembly of the 787's horizontal tail in Salt Lake City. For example the forward fuselage comes from Kansas, the center fuselage from Italy, the aft fuselage from South Carolina, and wings from Japan fitted with Australian trailing edges and leading edges from Oklahoma. Boeing has elected to ground eight of its 787 Dreamliner planes due to a reported manufacturing issue with some of the model's fuselage sections. Boeing Co said late on Thursday it was in discussions with U.S. safety regulators about a manufacturing issue found last year in its 787 Dreamliner. And the tally of lost MAX orders this year is approaching 1,000 jets. Boeing 787 fuselage supplier suspends manufacturing . On March 28, workers at Boeing's Everett, Wash., plant bent the wing of a special test 787 by 150 percent of the most extreme forces it would experience in … The issues were related to two aft body fuselage sections, a Boeing spokesperson told the Air Current. Boeing on Tuesday disclosed a new manufacturing quality issue with the 787 Dreamliner, this time with assembly of the airplane's horizontal tail in Salt Lake City. Section 41 arrives from Wichita as one piece. Boeing has found manufacturing defects on some of its 787 long-range airliners in areas where parts of the fuselage are joined together, the latest setback for the aircraft maker whose 737 Max is still grounded after two deadly crashes. Starting early next year, Boeing South Carolina will mill and drill composite fuselage sections for the 787 Dreamliner through cryogenic machining. That entire fuselage structure is flown to Everett for final assembly. Pioneered by Boeing, one-piece barrel construction method is available only on the 787. The company also is examining new Dreamliners for a separate fuselage issue, which came to light late last month when Boeing told 787 operators to ground eight of the jets. Boeing said in August that airlines operating its 787 Dreamliners had removed eight jets from service as a result of two distinct manufacturing issues in fuselage sections. Boeing instructed its customers to put eight recently-built 787 Dreamliners on the ground, as a risk of a structural failure was identified by the manufacturer itself. Boeing has dealt with 787 fuselage-shimming problems in the past. Eight Boeing 787 Dreamliner jets were removed from service for repairs due to manufacturing issues discovered in the fuselage. Boeing said in August airlines operating its 787 Dreamliners had removed eight jets from service as a result of two distinct manufacturing issues in fuselage sections. The fully integrated, composite structure section is known as section 41, and it’s built using auto fiber placement machines that wind composite tape into a one-piece fuselage section. Boeing selected two new engines to power the 787, the Rolls-Royce Trent 1000 and General Electric GEnx. FILE - In this April 28, 2013, file photo, a Boeing 787 lands after a test flight at Haneda International Airport in Tokyo. 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