The Federal Aviation Administration is currently investigating claims made by Boeing engineer Sam Salehpour regarding potential safety concerns with the 787 Dreamliner and 777 jets. Salehpour detailed his allegations in interviews with The New York Times and in documents sent to the F.A.A. According to Salehpour, the fuselage sections of the 787 Dreamliner are improperly fastened together, which could lead to potential mid-flight breakages after thousands of trips. He pointed out that changes in how the sections were fitted and fastened together during the assembly process could pose a risk to the structural integrity of the aircraft.

Boeing has denied these claims, stating that they have conducted extensive testing on the Dreamliner and determined that there is no immediate safety of flight issue. The company acknowledged that manufacturing changes were made but assured that they did not impact the durability or safe longevity of the airframe. Boeing spokesperson Paul Lewis emphasized that the company is not rushing the analysis to ensure a comprehensive assessment of any potential long-term fatigue concerns for the fleet.

Despite Boeing's reassurances, the FAA has confirmed that they are investigating Salehpour's allegations. The agency has met with the whistleblower and is taking the claims seriously. Salehpour's attorneys, Debra Katz and Lisa Banks, have accused Boeing of dismissing safety and quality concerns raised by Salehpour during the production process in favor of expediting the planes to market. Boeing shares fell 2% following the news of the FAA investigation.

Boeing has implemented "join verification" into its production processes after slowing output and halting deliveries for nearly two years in response to employee-identified issues on the 787. The company maintains that there are no near-term safety concerns for the in-service fleet and that the 787 will maintain its strength, durability, and service life. Salehpour's allegations are set to be discussed in a Senate Homeland Security and Governmental Affairs subcommittee later this month.

The FAA has encouraged voluntary reporting without fear of reprisal in the aviation industry and stated that they thoroughly investigate all reports. Boeing is already facing challenges with production delays and reduced aircraft deliveries for carriers like United Airlines and Southwest Airlines. The company is also dealing with fallout from an emergency on an Alaska Airlines flight involving a 737 Max plane.