More Than Just A Pretty (Composite) Face

While it's true most of the hype surrounding Boeing's forthcoming 787 Dreamliner concerns its composite fuselage structure, the planemaker notes the airliner will feature a number of new technologies within its carbon-fiber hull -- from shadeless windows, to lighting systems Boeing says will ease passenger fatigue, and could even make onboard meals more presentable in appearance.

The Associated Press reports Boeing maintained two seemingly opposite goals when designing the Dreamliner: low cost, and increased passenger comfort. Some efforts met both goals: a significant reduction in wiring, for example (from 91 miles of wiring in a 767, to 61 miles in a 787) allows more room for larger overhead bins, as well as thinner cabin walls that allow more elbow room.

Less wiring also means lighter in-flight entertainment systems. IFE systems in the first Dreamliners may carry some extraneous weight, however, in the form of tiny keyboards... which should one day allow passengers to conduct instant messaging conversations while inflight.

But not yet... especially as Boeing's Connexion wireless program went the way of the dodo last year, which in turn led to the scrapping of a planned wireless 787 entertainment system announced in January.

Leaning more towards the "comfort" side of the cost/benefit equation is Boeing's cabin lighting system -- which will be able to simulate sunrise, to better acclimate passengers on a red-eye flight. Larger cabin windows also sport variable opacity technology, which will allow passengers (and flight attendants) to gradually dim and brighten outside lighting, without the use of plastic shades.

The 787 also features an air-purification system, aimed at reducing the stench of onboard contaminants such as perfume and hairspray. The air onboard the Dreamliner will also be more humid than the typically bone-dry atmospheric conditions onboard current pressurized airliners, and will be pressurized to an altitude 2,000 feet lower than the current 8,000 ft. MSL standard.

Less noticeable to passengers -- at least, Boeing hopes so -- will be the 787's vertical gust suppression software, intended to smooth out the aircraft's response to turbulence while cruising on autopilot. The system is part of a flight control system less than a quarter the size of those on the current 777, Boeing's last clean-sheet airliner.

"We've taken out the hills and turned them into bumps," said 787 system integration director Mike Sinnett.

In a similar vein, cockpit head-up displays will allow pilots to better align the aircraft while on final approach -- which should, in theory, lead to smoother landings. Several airlines told Boeing more precise landings lead to cost savings, by easing wear and tear on the plane's tires.

Engineers working on various systems onboard the Dreamliner worked in tandem, Sinnett notes, which should lower the number of systems integration conflicts down the line.

"It's unlike anything we've ever done before, and as a result, I think we've hit the sweet spot in so many more areas than we would have otherwise," Sinnett said.

But as with any new aircraft design, problems inevitably occur. In fact, engineers have already identified approximately 750 problems, according to flight engineer Pete ban Leynseele. But Boeing isn't panicking, as those problems cropped up in the Integration Test Vehicle lab, an area nicknamed the "Iron Bird" -- allowing many of those problems to be solved before production of the first 787 began.

"This is where the lab pays for itself right now," said Iron Bird team leader Len Inderhees, "by finding the problems early before the airplane gets a similar problem up there in the factory or in flight test."

Issues do still remain, however -- most notably, Boeing's admission the first Dreamliners will not meet the company's weight targets. But those planes are test articles, and Boeing has stressed before customer planes will be on target.

But nevermind that... you want to hear how onboard lighting can make food more appetizing, right? On this one, Boeing cabin systems director Sean Sullivan realizes he faces a skeptical audience.

"Trust me," he said, "your food will look great. If you do it wrong, you can make your food look really bad."

FMI: www.boeing.com