How Boeing Refined the 787's Early Production Design

Boeing made design changes during the 787’s early production period as engineers addressed weight and structural considerations. The 787 entered commercial service with launch operator All Nippon Airways in October 2011.

Key details

• A 2009 wing-bend test reportedly identified high stress around the wing-to-fuselage area.
• Reported modifications to early aircraft included stringer notches and metal reinforcement fittings.
• Contributing weight factors cited in coverage included conservative composite design and early electrical systems and equipment.

A reported 787 prototype weighed about 22,000 pounds more than its design target.

Why it matters

The 787’s early development illustrates how aircraft designs evolve through testing and production experience. For airlines and passengers, those refinements form part of the engineering work behind bringing a new long-haul aircraft into service.