In June 2025, Air India Flight AI171, a Boeing 787 Dreamliner, tragically crashed shortly after takeoff while en route from India to London. The aircraft, carrying 242 passengers and crew, issued a Mayday call but reached only 825 feet before descending. Preliminary investigations suggest a combination of flap misconfiguration, excessive takeoff weight, and procedural errors. Imagery shows the wing flaps set dangerously low, between 0 to 5 degrees, far below the standard 15-degree setting necessary for safe takeoff. This misconfiguration, coupled with extreme heat reducing air density, limited the aircraft’s lift. Additionally, the aircraft took off from an intersection, reducing the available runway length to 1800 meters, further complicating the takeoff under a high fuel and passenger load.
Experts are examining whether pilot error or system misinterpretation led to the improper configuration. The Boeing 787’s flight management system relies heavily on manual input for weight and balance data. Incorrect data entry can prevent alerts for improper configuration until the aircraft exhibits abnormal behavior, such as a stall. With no automatic safeguards to prevent takeoff under these conditions, the flight proceeded as if all systems were in order.
Video footage shows the aircraft attempting to pitch up before impact, indicating that the pilots were trying to generate lift, but the aircraft lacked the necessary aerodynamic conditions. The high pitch attitude observed suggests a stall, where the angle of attack exceeds critical limits, disrupting airflow and lift.
While other theories, such as engine failure or bird strikes, have been considered, early evidence points to configuration errors and weight miscalculations. The investigation will scrutinize data from the cockpit voice recorder, flight data recorder, and other telemetry. It will also review maintenance logs, crew experience, and load planning documentation to determine the exact sequence of failures.
This incident highlights the potential for small errors to escalate into catastrophic events, especially when compounded by environmental factors and operational shortcuts. Air India’s safety practices are under scrutiny, as the airline has faced criticism over pilot training and maintenance standards. Since its acquisition by the Tata Group in 2022, improvements have been made, but legacy issues persist, as demonstrated by this tragic event.
