Boeing 787 leads 2024 sales after grounding
Despite a seven-month fleet grounding in 2013 and subsequent production halts, the Boeing 787 became the best-selling widebody aircraft in 2024.
The Boeing 787 Dreamliner was the best-selling widebody aircraft in 2024. This achievement came despite a seven-month global grounding of the fleet in 2013 and further delivery halts due to production issues between 2020 and 2023.
Boeing's original vision for the aircraft was radical. It bet on efficiency and flexibility over sheer size. The goal was to enable direct, long-haul routes between cities previously considered uneconomical.
A Troubled Path to Service
The program faced severe delays from the start. Boeing's ambitious global outsourcing strategy led to integration problems. The first delivery, originally planned for 2008, did not occur until late 2011.
When it entered service with All Nippon Airways in October 2011, the 787 was a technological leap. Passengers benefited from features like cabin pressure equivalent to 6,000 feet and higher humidity. Airlines quickly saw the promised fuel savings.
The 2013 Battery Crisis
A major crisis erupted in January 2013. Two separate incidents involving lithium-ion batteries resulted in fires. One occurred on a Japan Airlines aircraft in Boston; another happened on an All Nippon Airways flight in Japan.
Aviation regulators, led by the US Federal Aviation Administration, grounded the entire global fleet. Approximately 50 aircraft were pulled from service. The grounding lasted for several months.
Boeing redesigned the battery system with improved insulation and a containment box. Regulators approved the fix after about three months, and operations resumed.
Production Halts and Recovery
A different challenge emerged in the 2020s. Boeing identified manufacturing defects in areas like fuselage joins. These issues were not immediate safety threats but required extensive rework.
Deliveries were halted multiple times. At one point, the pause lasted nearly a full year, creating a backlog of over 100 aircraft. Boeing's production rate plummeted.
| Issue Period | Primary Cause | Approximate Delivery Halt Duration | Fleet Impact |
|---|---|---|---|
| 2013 | Lithium-ion battery fires | ~3 months | ~50 aircraft grounded globally |
| 2020-2023 | Manufacturing defects (fuselage joins, etc.) | Multiple halts, up to ~1 year | Over 100 undelivered aircraft backlog |
Despite these protracted problems, the 787's fundamental economics proved compelling. The aircraft's fuel burn is roughly 20% lower than older models like the 767. This translates to major annual savings for operators, a key factor tracked in industry stats.
The program's resilience was tested again in 2025. An Air India 787 crashed after takeoff, marking the type's first fatal accident. Investigations found no immediate evidence of a systemic design flaw affecting the fleet. Regulators did not order a grounding.
Airlines continued operations. No widespread cancellations followed. The 787's route network, central to many airline fixtures, remained largely intact. By 2024, the accumulated orders and deliveries overcame the shadow of its past troubles, securing its position as the widebody sales leader.
