Boeing Grounds 777X Test Fleet Amid Structural Cracks, Delays Loom

Boeing (BA.US) has discovered structural cracks in its 777X aircraft during the aircraft's first flight tests. As of August 20th, the company announced that it has grounded its test fleet to replace the faulty component and investigate the cause of the issue.
According to sources, Boeing identified similar issues in two active test aircraft, leading to the immediate halt of further flight plans. The problem was first detected on August 16th when a Boeing 777-9 test plane, designated WH003, took off from Kona Airport in Hawaii and flew for 5 hours and 31 minutes before the cracks in the critical engine component were found.
This key part attaches the massive engine, developed by General Electric, to the aircraft's wing. During the first flight, cracks appeared, leading Boeing to notify federal regulators and customers. The company, holding 540 new aircraft orders, aims to begin deliveries in 2025, though it's unclear if the issue will impact delivery timelines.
The 777X, Boeing's latest generation of twin-aisle aircraft, promises enhanced fuel efficiency and spacious cabin design, making it highly anticipated in the market. However, this incident casts a shadow over its future. This issue marks the latest setback in Boeing's certification of its largest aircraft, a process already delayed by roughly five years. The company started flight testing in July with help from U.S. regulators, a significant milestone.
Since an in-flight explosion incident earlier this year, Boeing has faced continuous scrutiny regarding its manufacturing and safety standards. Royal Bank of Canada Capital analyst Ken Herbert suggested that the grounding might delay the 777X's delivery expectations, potentially pushing them to 2026. He speculates that the project may undergo "a lengthy approval process."
While Boeing conducts inspections on other planes in the 777X testing fleet, there are no plans to resume flight tests soon. General Electric's GE9X turbofan engine, the largest and most powerful commercial jet engine to date, remains unaffected. Boeing has communicated the engine strut issue to the Federal Aviation Administration (FAA) and its customers.
In response to the discovery, Boeing stated that the affected part, which connects the engine to the aircraft body, needs to be replaced. The company emphasized its commitment to resuming flight tests once they address the issue and absorb the lessons learned. Earlier quality concerns had already been identified in Boeing aircraft, marking an additional challenge for the aviation giant.
Despite these efforts, the recent issue impacts Boeing’s progress significantly. Known as a critical phase in the 777X project, delays in flight tests could hamper the aircraft’s certification and delivery, adding to Boeing's list of challenges as it navigates through an ongoing period of setbacks.