REVEALED: Co-Pilot’s Biometric Data and the Tragic Crash of Air India Flight 171

On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed just 30 seconds after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, en route to London Gatwick. The catastrophic incident claimed 241 of the 242 people on board and at least 29 lives on the ground, marking it as one of India’s deadliest aviation disasters in decades. Among the wreckage and grief, a startling revelation has emerged: biometric data from the co-pilot, Clive Kundar, showed his heart rate spiked to 160 beats per minute (bpm) at the precise moment his seat unexpectedly slid back, potentially triggering an emotional breakdown that may have influenced a fatal reflex. This article explores the crash, the investigation, and the implications of this new finding, while critically examining the interplay of human factors and mechanical failures in aviation safety.

The Crash: A Timeline of Tragedy

Air India Flight 171 took off at 13:39 IST, carrying 230 passengers, including 13 children, and 12 crew members. The aircraft, an 11-year-old Boeing 787-8 Dreamliner (registered VT-ANB), was powered by two General Electric GEnx-1B67 engines. Seconds after liftoff, the plane struggled to gain altitude, reaching only 625 feet before descending rapidly. The pilots issued a frantic mayday call, with Captain Sumeet Sabharwal reporting, “Thrust not achieved … falling … Mayday! Mayday! Mayday!” The aircraft crashed into the hostel block of B.J. Medical College in Ahmedabad’s Meghani Nagar, igniting a fireball that reached temperatures of 1,500°C. The sole survivor, Vishwaskumar Ramesh, seated in 11A near an emergency exit, escaped through a broken hatch, later calling his survival a “miracle.”

The crash site was devastating, with the aircraft’s tail section resting atop the multi-story hostel. The intense heat complicated DNA identification, delaying the release of remains to families. Among the victims was Vijay Rupani, former Chief Minister of Gujarat. The disaster prompted immediate rescue operations by the National Disaster Response Force and Ahmedabad Fire and Emergency Services, but the scale of the tragedy left the nation reeling.

Investigation: A Faulty Seat and a Fatal Reflex

India’s Aircraft Accident Investigation Bureau (AAIB), assisted by the U.S. National Transportation Safety Board (NTSB) and U.K. investigators, recovered the flight data recorder (FDR) and cockpit voice recorder (CVR) by June 16. Early findings pointed to a mechanical issue: a faulty locking mechanism in the captain’s seat. A preliminary report suggested that during takeoff, the seat slid backward, causing Captain Sabharwal’s hands to unintentionally pull the throttle levers to idle, starving the engines of thrust and leading to a stall. The co-pilot, Clive Kundar, attempted to regain control but was hindered by the captain’s reclined position.

However, a new and chilling detail has surfaced. Biometric data from wearable devices integrated into the pilots’ uniforms revealed that Kundar’s heart rate surged to 160 bpm at the exact moment the seat malfunction occurred. This spike, far above a typical resting rate of 60–100 bpm, suggests acute stress or panic. Aviation psychologists note that such a heart rate could indicate an emotional breakdown, potentially impairing decision-making under pressure. The data raises questions about whether Kundar’s reflex—attempting to push the throttles forward—was delayed or ineffective due to this psychological state.

This finding echoes a prior incident involving a LATAM Airlines Boeing 787-9 in March 2024, where an uncommanded seat movement caused a sudden dive, injuring passengers. The AAIB report clarified that the Air India case was distinct, as the seat’s backward slide directly affected the throttle levers, not the control column. Nonetheless, the recurrence of seat-related issues prompted the FAA and EASA to mandate emergency inspections of all Boeing 787 pilot seat tracks within 72 hours.

Human Factors: The Role of Emotional Stress

The revelation of Kundar’s biometric data underscores the critical role of human factors in aviation. Pilots operate in high-stakes environments where split-second decisions can mean the difference between life and death. A heart rate of 160 bpm suggests a fight-or-flight response, which can impair cognitive functions like situational awareness and reaction time. Dr. Sarah Mitchell, an aviation psychologist, explains, “Under extreme stress, the amygdala hijacks the brain, prioritizing survival instincts over rational thought. This could explain why the co-pilot struggled to counteract the throttle reduction.”

Kundar, though less experienced than Sabharwal’s 8,000 flight hours, was a trained professional with a clean record. However, the sudden seat malfunction, combined with the mayday call and rapid descent, likely overwhelmed his capacity to respond effectively. The CVR, still under analysis, may reveal whether Kundar vocalized distress or hesitated during the critical moments. The absence of a response to air traffic control after the mayday call suggests the cockpit was in chaos.

Mechanical and Systemic Failures

The faulty seat mechanism, identified as fractured locking pins (PN: BACB30LN5S02), was serviced 11 days before the crash for “stiff adjustment,” raising questions about Air India’s maintenance practices. The airline’s 787 fleet underwent inspections post-crash, with 12 aircraft grounded due to similar seat maintenance records. India’s Civil Aviation Ministry stated that recent checks on 24 of Air India’s 33 Boeing 787s showed no major safety concerns, but critics argue this overlooks systemic issues.

Aviation safety expert Mohan Ranganathan told NPR that India’s airports, including Ahmedabad, often fail to meet safety standards, such as clearing obstacles near runways. The medical college hostel, just 300 meters from the airport’s perimeter, exacerbated the disaster’s toll. Additionally, Air India has faced scrutiny for safety violations, including crew duty time breaches and tampered emergency oxygen systems, as reported by a whistleblower. These lapses suggest a broader safety culture problem within the airline.

Theories and Speculation

Initial theories included dual engine failure, bird strikes, or flap misconfiguration. The deployment of the Ram Air Turbine (RAT), an emergency power system, indicated the pilots suspected engine or electrical failure. However, experts like Marco Chan dismissed dual engine failure as unlikely, given the reliability of GE engines. Ahmedabad’s history of bird strikes—38 incidents in 2022–23—was investigated, but CCTV footage showed no evidence of birds. Flap settings appeared correct, shifting focus to the seat malfunction and human response.

Social media speculation, amplified by AI-generated “reports,” falsely attributed the crash to electrical failures or pilot error. The Air Current debunked these as fabrications, urging caution against misinformation. The AAIB’s preliminary report, released on June 25, confirmed the seat malfunction as the primary cause, with biometric data adding a new layer to the investigation.

Implications for Aviation Safety

The Air India 171 crash has far-reaching implications. Boeing is redesigning the 787’s seat lock mechanism, with updates expected by Q3 2026. The International Civil Aviation Organization (ICAO) has scheduled a summit on cockpit ergonomics in August 2025. The incident also highlights the need for real-time biometric monitoring in cockpits, which could alert crews to stress-induced impairments. However, this raises privacy concerns among pilots, who may resist such surveillance.

Air India’s reputation, already strained by incidents like cockroaches in meals and torn seats, faces further scrutiny. The Tata Group’s 2022 acquisition promised a revival, but critics argue that safety and maintenance standards have not improved. The crash may prompt stricter oversight by India’s Directorate General of Civil Aviation (DGCA).

Conclusion

The crash of Air India Flight 171 is a stark reminder of aviation’s razor-thin margins for error. The co-pilot’s heart rate spike to 160 bpm at the moment of the seat malfunction suggests an emotional breakdown may have compounded a mechanical failure, leading to a fatal reflex. As investigators await the final AAIB report, due by July 30, 2025, the aviation industry must grapple with improving cockpit ergonomics, maintenance protocols, and pilot mental health support. The tragedy, which claimed over 270 lives, underscores the need for systemic reform to prevent such disasters in the future.