Jon Ostrower (Flightblogger) from Flight International magazine reported that the prime reason for the production halt was not just for suppliers to catch up with production work but also to allow Boeing and it’s suppliers to fix a design flaw. The flaw can potentially compromise the structural integrity of the airplane.Flightblogger reported that the flaw was discovered in December, 5 months ago.
The flaw involves shear ties which attaches the fuselage skin to the fuselage structure in section 48 and 48 aft. When there are repeated changes in the thermal condition of the rear fuselage, the shear ties can detach from the aircraft skin thus creating the structural issue.
Flightblogger reports that the situation does not represent an immediate safety of flight issue to the test flight fleet and that a fix is identified. The fix involves using thicker shear ties and radius filler alongside the existing shear ties. Boeing says that all airplanes will meet FAA requirements.
Boeing said that the issue will not effect first delivery or continued production of the 787.
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