section_path: Design/Airframe
section_name: Airframe
paragraph_text: Airframe
  
  The 787 is the first commercial aircraft to have an airframe majority made of carbon fiber reinforced polymer (CFRP), applied in: the empennage, fuselage, wings, doors, and in most other main components. Each 787 contains approximately 77,000 lb (35 t) of CFRP, made with 51,000 lb (23 t) of pure carbon fiber. CFRP materials have a higher strength-to-weight ratio than conventional aluminum structural materials, which contributes significantly to the 787's weight savings, as well as superior fatigue behavior. Historically, the first CFRP primary structure in Boeing commercial aircraft was put into service in 1984 on the horizontal tail of the Boeing 737 Classic, and in the mid-1990s on both vertical and horizontal tail (empennage) of the Boeing 777. In the early 2000s, while studying the proposed Sonic Cruiser, Boeing built and tested the first CFRP fuselage section for commercial aircraft, a 20-foot (6.1-meter) long anechoic chamber, which later applied to the Dreamliner. Instead of designing one-piece composite fuselage barrels like the 787, the competing Airbus A350 uses a slightly more conventional approach with CFRP panels on CFRP frames, which is considered less risky in terms of assembly tolerance between fuselage sections.
  
  Safety can be a concern due to lower impact energy absorption and poorer fire, smoke and toxicity capability of CFRP fuselages in the event of a crash landing, leading to whistleblower complaints at Boeing by Vince Weldon, who was fired in 2006. The Occupational Safety and Health Administration (OSHA) later denied Weldon whistleblower status "largely on the grounds that Boeing's 787 design does not violate any FAA regulations or standards". Boeing further argued that CFRP structures have been used on empennages and other parts of airliners for many years without incident, and special damage detection procedures will be instituted for the 787 to detect any potential hidden damage.
  
  In 2006, Boeing launched the 787 GoldCare program. This is an optional, comprehensive life-cycle management service, whereby aircraft in the program are routinely monitored and repaired, as needed. Although the first program of its kind from Boeing, post-sale protection programs are not new; such programs are usually offered by third party service centers. Boeing is also designing and testing composite hardware so inspections are mainly visual. This reduces the need for ultrasonic and other non-visual inspection methods, saving time and money.