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Boeing 787


Keshav V.

on 17 February 2012

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Transcript of Boeing 787

More Facts Research My Project on
the Boeing 787 Notes Important
Details By Keshav Vedula General Facts The Boeing 787 has two powerful jet engines and it is a commercial aircraft. It is very fuel efficient and it consumes 20% less fuel than a similar model, like the Boeing 767. The interior of the Boeing 787 aircraft is truly luxurious. There is everything from 1 bedroom suites to conference rooms inside a Boeing 787, yet it is still extremely light. It is made almost entirely out of carbon fiber composites and titanium. That is why it is very light for its size. The Boeing 787 Dreamliner Dreamliner Its materials, listed by weight, are 50% composites, 20% aluminum, 15% titanium, 10% steel, and 5% other. Quick Facts Range:
7,650 to 8,200 nautical miles (14,200 to 15,200 km) Seating:
210 to 250 passengers Wing Span:
197 feet (60 meters) Length:
186 feet (57 meters) Height:
56 feet (17 meters) Cruise Speed:
Mach 0.85

Total Cargo Volume:
4,400 cubic feet The Boeing 787 is the latest commercial aircraft manufactured by Boeing. The Boeing 787 was scheduled to enter commercial air service in May of 2008 but due to shortage of parts and technical issuses, it was delayed. It finally became available October 26, 2011 for commercial air flight. The Boeing 787's first test flight was in late December 2009. However it wasn't commercially available until after 2 years of rigorous testing. The Boeing 787's Efficient Interior and Exterior Design As I stated earlier, it's materials listed by weight, are 50% composite, 20% aluminum, 15% titanium, 10% steel, and 5% other. Aluminum is used on the wing and the tail leading edges, titanium is used mainly on engines and fasteners, and steel is used in various places. External features include raked wingtips and engine nacelles with noise-reducing serrated edges. Materials The Boeing 787 interior width is 18 feet but its unique design allows it to seat more passengers. It also allows the lavatories to be more spacious. Each 787 contains approximately 35 short tons of carbon fiber (80% of the plane's volume) reinforced plastic, and with 23 tons of plain carbon fiber. Carbon fiber composites have a higher strength-to-weight ratio than standard aircraft materials, and help make the 787 a lighter aircraft. Spacious and Advanced Weight / Materials On the production of
The Boeing 787 Before we start off our story on how the boeing 787 was produced, lets begin with how the idea of building an efficient aircraft came about. During the late 1990s, Boeing began considering replacement aircraft programs as sales for the 767 and Boeing 747 slowed. The company proposed two new aircraft ideas, the 747X, which would have lengthened the 747-400 and improved efficiency, and the Sonic Cruiser, which would have achieved 15% higher speeds (approximately Mach 0.98) while burning fuel at the same rate as the existing 767. Many people liked the idea of the Sonic Crusier however, they were very concerned about the cost and saftey issuses. However, tides turned after September 11, 2001 and airlines were looking for efficient and safe aircrafts instead of fast ones. Boeing therefore cancelled the idea of the Sonic Crusier and started working on an efficient and safe aircraft we now call the Boeing 787 Dreamliner. That is basically how the boeing 787 originated. How the Boeing 787 Originated On December 16, 2003, Boeing announced that the aircraft would be assembled in its factory in Everett, Washington. Boeing requested that the suppliers (companies in Korea, Japan, Italy, France, USA, and India) for the aircraft parts, assemble most of the parts before they shipped them to Washington. Therefore very little assembly would take place in Washington which would speed the production of the aircraft.

To speed the delivery of the 787's major components, Boeing modified several used 747 into 747 Dreamlifters to transport 787 wings, fuselage sections, and other smaller parts. Japanese industrial participation was very important to the project, with a 35% work share, the first time Japanese firms had taken a lead role in mass production of Boeing airliner wings, and many of the subcontractors were supported and funded by the Japanese government. Japanese manufacturer Toray Industries and Boeing announced a production agreement involving $6 billion worth of carbon fiber, extending a 2004 contract and aimed at easing production concerns.

Manufacturing and Suppliers Production and Delivery Days While producing the Boeing 787, manufacturers noticed that the frame of this aircraft was obviously too heavy. To fix this problem they tried to trim excess weight wherever they could. Part of this process involved redesigning certain parts and replacing steel with titanium. Boeing had originally planned for a first flight by the end of August 2007 and organized the first 787 rollout ceremony to be on July 8, 2007. However at that time the aircrafts major electical systems and controls weren't installed yet. In addition to that many suppliers for the aircraft had difficulty pre-assembling important parts which delayed the first flight even more. On September 5, Boeing announced a three-month delay, blaming a shortage of fasteners as well as incomplete software. On October 10, 2007, a second three-month delay to the first flight and a six-month delay to first deliveries was announced due to problems with the foreign and domestic supply chain, including an ongoing fastener shortage, the lack of documentation from overseas suppliers, and continuing delays with the flight guidance software. Less than a week later, Mike Bair, the 787 program manager was replaced. On January 16, 2008, Boeing announced a third three-month delay to the first flight of the 787. On March 28, 2008, in an effort to gain more control over the supply chain, Boeing announced that it planned to buy manufacturing companies. On April 9, 2008, Boeing officially announced a fourth delay, shifting the first flight to the fourth quarter of 2008. On November 4, 2008, the company announced a fifth delay due to incorrect fastener installation and the Boeing machinists stated that the first test flight would not occur in the fourth quarter of 2008. After assessing the 787 program schedule with its suppliers, Boeing confirmed on December 11, 2008 that the first flight would be delayed until the second quarter of 2009. As you can see the boeing 787 took a LONG time to manufacture.

Delivery Delays After the Boeing 787 finally got manufactured, it took its first flight on December 15, 2009, and began a series of test flights, including the vertical drop and the engine failure. They also tested the landing gear several times. Many of the test flights were designed to test the efficiency and safety of the 787. After completing the test flights the 787 was considered a sucess. It entered commercial air service on October 26, 2011. Test Flights Role:
Wide-body jet airliner
National origin:
United States Manufacturer:
Boeing Commercial Airplanes

First flight:
December 15, 2009

October 26, 2011, with All Nippon Airways (ANA) Primary user:
All Nippon Airways
Program cost:
$32 billion
Unit cost:
787-8: US$193.5 million (2011)
787-9: US$227.8 million (2011)
Boeing states that the 787 is the company's most fuel-efficient aircraft and the world's first major airplane to use composite materials for most of its construction. The 787 consumes 20% less fuel and emits 20% less emissions than the similarly-sized Boeing 767, which was one of Boeing's main goals while constructing the 787. Most of its efficiency comes from its engines, advanced systems, and from its a aerodynamic improvements. The 787's engines use all-electrical bleedless systems, eliminating the superheated air conduits normally used for aircraft power, de-icing, and other functions. This allows the engines to be much quieter. The 787 was designed to become the first production composite airliner, with the fuselage assembled in one-piece composite barrel sections instead of the multiple aluminum sheets and some 50,000 fasteners used on an existing aircraft. Boeing selected two new engine types to power the 787, the General Electric GEnx and Rolls-Royce Trent 1000.
Holes drilled into fueslage during assembly:
787 - fewer than 10,000
747 - 1 million holes

787 vs. 747 on composites and aluminum ( by weight )

50 percent composites
20 percent aluminum

12 percent composites
50 percent aluminum

Hours of Wind Tunnel Testing
15,000 hours of wind tunnel tests Efficiency Design Interesting Facts Amount of Copper Wiring Eliminated
60 miles The big difference between the 787 and the 767 is that the 787 uses much more electrical systems and since most companies weren't fimilar with this type of technology, it slowed the production of the 787. Amount of Energy Consumed and Generated
1.5 mega watts ( enough electricity to power 750-1000 homes) The Boeing 787 in the Future Engineers and scientists are currently working on the 787-9. This is an improved version of the 787 which is targeted to compete with the Airbus A380. The 787-9 can hold 260-300 passengers and it travels in a range from 8,000 - 8,500 nautical miles. It has the same wingspan and height as the 787 but a slighly larger length. The 787-9 also has lots of cargo space. As of now its first flight is planned for 2014. As I stated earlier, the boeing 787 was tested many times, but just to give you an idea, it was tested at NASA, a flight research center in France, and at a specialized wind tunnel in UK. Biliography Boeing (1995-2011) . Boeing 787 Dreamliner Will Provide New Solutions for Airlines. In Boeing Commercial Airplanes (787 Dreamliner).
Retrieved from

Gates, D. (2009) . Boeing Still Sure Delayed 787 Will Be Profitable. In The Seattle Times (Boeing Areospace)
Retrieved from http://seattletimes.nwsource.com/html/boeingaerospace/2009760894_boeingdelay28.html

Flightglobal (2011) . Boeing - 787-8. In Commercial Aircraft Directory - Aircraft Specification (Boeing) .
Retrieved from http://www.flightglobal.com/directory/detail.aspx?aircraftCategory=CommercialAircraft&manufacturerType=CommercialAircraft&navigationItemId=389&aircraftId=3272&manufacturer=3005&keyword=&searchMode=Manufacturer
The interior of the Boeing 787 also reflects its complex and advanced systems. Allow me to show you what I am talking about. Advancements in window technology Lighting Enhancements
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