The Boeing 787 Dreamliner is an American wide-body jet airliner developed and manufactured by Boeing Commercial Airplanes. After dropping its unconventional Sonic Cruiser project, Boeing announced the conventional 7E7 on January 29, 2003, which focused largely on efficiency. The program was launched on April 26, 2004, with an order for 50 aircraft from All Nippon Airways (ANA), targeting a 2008 introduction. On July 8, 2007, a prototype 787 was rolled out without major operating systems, and then the aircraft experienced multiple delays until its maiden flight on December 15, 2009. Type certification was received in August 2011 and the first 787-8 was delivered in September 2011 before entering commercial service on October 26, 2011, with ANA.
At launch, Boeing targeted the 787 with 20% less fuel burn than replaced aircraft like the Boeing 767, carrying 200 to 300 passengers on point-to-point routes up to 8,500 nautical miles [nmi] (15,700 km; 9,800 mi), a shift from hub-and-spoke travel. The twinjet is powered by General Electric GEnx or Rolls-Royce Trent 1000 high-bypass turbofans. It is the first airliner with an airframe primarily made of composite materials and makes extensive use of electrical systems. Externally, it is recognizable by its four-window cockpit, raked wingtips, and noise-reducing chevrons on its engine nacelles. Development and production rely increasingly on subcontractors around the world, with final assembly at Boeing South Carolina in North Charleston, after being assembled in the Boeing Everett Factory in Washington until March 2021.
The initial 186-foot-long (57 m) 787-8 typically seats 242 passengers over a range of 7,355 nmi (13,621 km; 8,464 mi), with a 502,500 lb (227.9 t) MTOW compared to 560,000 lb (250 t) for later variants. The stretched 787-9, 206 ft (63 m) long, can fly 7,635 nmi (14,140 km; 8,786 mi) with 290 passengers; it entered service on August 7, 2014, with ANA. The further stretched 787-10, 224 ft (68 m) long, seating 330 over 6,430 nmi (11,910 km; 7,400 mi), entered service with Singapore Airlines on April 3, 2018.
Early 787 operations encountered several problems caused mainly by its lithium-ion batteries, which culminated in fires onboard some aircraft. In January 2013, the U.S. FAA grounded all 787s until it approved the revised battery design in April 2013. Significant quality control issues from 2019 onwards caused a production slowdown and, from January 2021 until August 2022, an almost total cessation of deliveries. Due to ballooning production costs, Boeing has spent $32 billion on the program; estimates for the number of aircraft sales needed to break even vary between 1,300 and 2,000. As of November 2023, the 787 program has booked a total of 1,843 orders and made 1,099 deliveries while recording zero fatalities and no hull losses.