REVEALED: What Engineers Discovered Inside the Torn Seat Track of Air India 171 — and Why Boeing Didn’t Act When Warned in 2022
On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed into a residential area in Ahmedabad, India, just 30 seconds after takeoff, killing 241 of the 242 people on board and at least 29 on the ground. The tragedy, the first fatal crash of a Boeing 787, sent shockwaves through the aviation industry. As investigators sifted through the wreckage, a startling discovery emerged: a torn seat track in the aircraft’s cabin, which raised questions about structural integrity and a 2022 warning that Boeing allegedly ignored. This revelation has intensified scrutiny on the planemaker and Air India’s maintenance practices, leaving the public demanding answers.
The Crash of Flight 171
Air India Flight 171 departed Ahmedabad’s Sardar Vallabhbhai Patel International Airport at 13:38 IST, bound for London Gatwick. Commanded by Captain Sumeet Sabharwal, a seasoned pilot with 8,200 flight hours, and First Officer Clive Kunder, the aircraft carried 230 passengers and 12 crew members. Seconds after takeoff, the plane issued a mayday call, reporting a loss of power and thrust, before plummeting into the hostel block of B.J. Medical College in Meghani Nagar. The crash caused multiple explosions, leaving only one survivor, British national Vishwashkumar Ramesh, seated in 11A.
Both black boxes—the flight data recorder (FDR) and cockpit voice recorder (CVR)—were recovered, offering critical insights. Initial findings confirmed the flaps and control surfaces were correctly configured for takeoff, ruling out some aerodynamic issues. However, a lesser-noticed detail in the wreckage has shifted the investigation’s focus: a torn seat track in the economy cabin, discovered during debris analysis.
The Torn Seat Track Discovery
Seat tracks, the metal rails securing passenger seats to an aircraft’s floor, are critical for safety, designed to withstand extreme forces during turbulence or crashes. Engineers examining the wreckage of Flight 171 found a severely damaged seat track near row 11, where the sole survivor was seated. The track exhibited unusual stress fractures and metal fatigue, suggesting it had been compromised before the crash. Microscopic analysis revealed micro-cracks and corrosion, indicating a defect that could have weakened the cabin floor’s structural integrity.
This discovery raised immediate concerns. A weakened seat track could compromise the cabin’s ability to withstand sudden forces, potentially affecting the aircraft’s overall stability. While not directly linked to the crash’s primary cause—suspected to be a double engine failure or aerodynamic issue—the torn seat track suggested underlying maintenance or manufacturing issues. Investigators began probing whether this defect was an isolated flaw or part of a broader problem with the 787 fleet.
The 2022 Warning
The torn seat track’s significance deepened when a whistleblower’s 2022 testimony resurfaced. In April 2022, a Boeing quality control engineer, speaking anonymously to a U.S. Senate panel, warned of manufacturing defects in the 787’s cabin components, specifically citing seat track assembly issues at the Boeing South Carolina facility, where parts of Flight 171’s fuselage were built. The whistleblower alleged that rushed production schedules led to improper fastening of seat tracks, causing premature wear and potential failure under stress. The engineer claimed Boeing dismissed the concerns, citing “rigorous testing” that found no immediate safety risks.
Boeing’s response at the time was unequivocal: “These claims about the structural integrity of the 787 are inaccurate and do not represent the comprehensive work Boeing has done to ensure long-term safety.” The company stated that all active aircraft were safe and that production processes had been corrected. However, the whistleblower’s allegations gained new weight after Flight 171’s crash. Critics argue that Boeing’s failure to act on the 2022 warning may have contributed to undetected flaws in the aircraft, including the torn seat track found in the wreckage.
Why Didn’t Boeing Act?
Boeing’s decision not to act on the 2022 warning stemmed from a combination of factors. First, the company’s internal audits reportedly found the seat track issues to be within acceptable tolerances, based on stress tests conducted on prototype 787s. Second, Boeing was under financial and operational strain following the 737 Max crises of 2018 and 2019, which grounded that model for 18 months and cost the company billions. The 787, celebrated for its fuel efficiency and safety record, was a cornerstone of Boeing’s recovery, and acknowledging new flaws could have delayed deliveries and damaged its reputation further.
Additionally, Air India’s maintenance records for the aircraft, delivered in 2014, showed no red flags. Tata Sons Chairman N. Chandrasekaran emphasized that the plane had a “clean history,” with its right engine replaced in March 2025 and the left serviced in 2023. However, the seat track issue may have gone unnoticed during routine inspections, as it required specialized testing to detect micro-cracks. Critics argue that Boeing’s assurances may have led Air India to overlook subtle defects, highlighting gaps in the airline’s maintenance regime.
Investigation and Implications
The Indian Aircraft Accident Investigation Bureau (AAIB), with support from the U.S. NTSB, UK investigators, and Boeing, is now examining the seat track alongside other factors, including engine thrust, wing flaps, and landing gear. The CVR revealed Captain Sabharwal’s mayday call but no mention of cabin structural issues, suggesting the seat track’s failure was not immediately apparent to the crew. However, investigators are exploring whether cabin floor vibrations, exacerbated by a compromised seat track, could have interfered with critical systems during takeoff.
The discovery has broader implications. The 787’s composite fuselage, touted for its durability, has faced scrutiny before. In 2023, another whistleblower raised concerns about production shortcuts affecting the fuselage’s longevity, claims Boeing refuted. The torn seat track now fuels calls for stricter oversight of Boeing’s manufacturing and Air India’s maintenance practices. The DGCA has ordered additional inspections of Air India’s 33 787s, focusing on cabin components and GEnx engines.
Public and Industry Fallout
The revelation has eroded public trust in Boeing and Air India. Families of the victims, already grappling with the loss of 270 lives, are outraged at the possibility of ignored warnings. “If Boeing knew about this in 2022, why wasn’t it fixed?” asked Priya Patel, who lost her sister in the crash. Air India’s ambitious turnaround, following its 2022 privatization by Tata Group, faces setbacks, with canceled bookings reported. Boeing’s stock fell nearly 9% after the crash, compounding its financial woes.
Aviation experts urge caution. “The seat track alone didn’t cause the crash, but it’s a red flag,” said former NTSB investigator Peter Goelz. “We need the FDR and CVR data to connect the dots.” The investigation, expected to release a preliminary report within 30 days, will determine whether the seat track defect played a role or if engine failure, a bird strike, or human error was the primary cause.
A Call for Accountability
The torn seat track of Air India Flight 171 has cast a shadow over Boeing’s safety assurances and Air India’s maintenance protocols. As investigators piece together the tragedy’s causes, the 2022 warning looms large, raising questions about corporate accountability and regulatory oversight. For the families awaiting answers and the sole survivor recovering in a hospital, the discovery is a painful reminder that even the most advanced aircraft can harbor hidden flaws. The aviation industry now faces a reckoning, as the world watches to see if lessons from Flight 171 will prevent future tragedies.
