Boeing Says Isolated Incident Won't Affect Schedule

We suspect structural engineers on Boeing's 787 program are working overtime on this one, after a required test for FAA certification was called off due to a possible defect in the aircraft's composite skin.

Business Week reports a 33-foot prototype section of the 787s fuselage -- which was to be used as part of an FAA test to certify the aircraft's manufacturing process -- displayed bubbles in the composite structure.

Boeing spokeswoman Yvonne Leach said the bubbles were likely caused by a leak in a pressing tool used to form the aircraft's fuselage, which allowed gases to seep into the composite material.

Over time, the bubbles could degrade and weaken the composites, which are used extensively in the 787's structure.

Despite the glitch, however, Boeing's expected 2008 certification for the Dreamliner is not likely to be affected.

"We know what happened," Mike Bair, vice president and general manager of the 787 program, told the Seattle Post-Intelligencer. "We learned some things as a result, which is part of what this whole process is about. We know what we have to do to support our certification plan."

Bair also noted the component that showed evidence of bubbling -- a central barrel section -- was one of nine that make up the 787's fuselage. Those eight other sections (including the complex nose and tail sections) showed no significant problems.

To make up time lost in the delay, Bair said the company will produce two identical components and test them concurrently.

FMI: www.boeing.com