A Boeing engineer turned whistleblower, Sam Salehpour, reiterated his claims that the 787 Dreamliner is unsafe due to assembly flaws. He expressed concerns about tiny nonconforming gaps found in multiple planes during fuselage assembly, which could lead to catastrophic outcomes. Salehpour said he would not put his family on a 787 Dreamliner right now. He is set to testify before a U.S. Senate subcommittee.

He doubled down on his claims Tuesday, saying that the plane could fall apart and “drop to the ground” midflight unless the alleged safety problems are addressed.

Boeing has faced increased scrutiny following a midflight blowout of a door panel from a 737 Max 9 during a flight in January. The company’s CEO, Dave Calhoun, has announced he will step down. Boeing has defended the structural integrity of the 787, stating that it was stress-tested for 165,000 cycles without failure. The company also said it had inspected 689 of the 787s in service and found no evidence of fatigue.

In a statement, Boeing said, “These claims about the structural integrity of the 787 are inaccurate. The issues raised have been subject to rigorous engineering examination under FAA oversight.”

Despite Boeing’s assurances, Salehpour remains firm in his claims and suggests that production of the 787 should be halted until the alleged problems are addressed. He has flagged the issue to the FAA, which is investigating his claims. Salehpour was transferred to work on the 777 line after raising concerns internally.

Salehpour’s attorney, Lisa Banks, has heard from additional whistleblowers at Boeing who have reported similar issues. Salehpour is confident in his allegations, citing Boeing’s own data and his experience as a quality engineer.

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Article generated from corporate media reports.