Besides its use of lithium batteries, the 787 is the first airliner whose structure is mostly made from composite materials rather than aluminum. The aircraft also relies to a greater extent than previous airliners on electronics to operate, rather than hydraulic or mechanical systems.
“You can go down the list of hardware on that plane where it’s the first time it has been used on an airplane,” said Paul Czysz, professor emeritus of aeronautical engineering at St. Louis University in St. Louis. “With anything that’s brand new and has never been used on an airplane before, you run the risk of being the first one to find out if it really works.”
The 787 was tested extensively both before and after its first test flight in 2009. The FAA said its technical experts logged 200,000 hours testing and reviewing the plane’s design before it was certified in August 2011.
Six test planes ran up some 4,645 flight hours. About a quarter of those hours were flown by FAA flight test crews, the agency said in 2011.
Associated Press writers Malcolm Foster in Tokyo and Joshua Freed in Minneapolis contributed to this report.
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