Boeing 737 MAX 9 Grounded After Fuselage Panel Rips Off in Midair Emergency

Federal aviation regulators have issued an urgent directive to ground specific Boeing 737 MAX 9 aircraft for immediate inspection following a harrowing midair incident on Friday. An Alaska Airlines-operated Boeing 737 MAX 9 experienced a rapid depressurization at 16,000 feet after a fuselage panel serving as a plug for an emergency exit door tore off during the flight from Portland, Oregon, to Ontario, California. The emergency led to an immediate return to Portland, where the aircraft safely landed with all 171 passengers and six crew members on board.

While no serious injuries were reported, some passengers suffered minor injuries, receiving prompt medical attention and subsequent clearance. Notably, the incident occurred in seats adjacent to the missing door plug, with parts of the seat and headrest missing.

The Federal Aviation Administration (FAA) responded promptly, issuing a directive on Saturday mandating safety inspections for all 171 Boeing 737 MAX 9 aircraft operating globally. Simultaneously, the National Transportation Safety Board (NTSB) deployed a specialized “Go Team” to investigate the incident, bringing expertise in structures, operations, and systems.

Why the Door Plug Panel?

The Boeing 737 MAX 9, the largest single-aisle plane in Boeing’s fleet with a seating capacity of up to 220 people, features an optional extra door to meet evacuation requirements. In configurations with fewer seats, an emergency door can be replaced with a panel, known as a door plug, providing flexibility in aircraft layouts across the industry.

Production Process Complexity

The door plugs for Boeing 737 MAX 9 planes are manufactured by Spirit AeroSystems in Kansas. The installation involves a two-part process, with Spirit producing the plug doors at their Wichita plant and Boeing completing the installation at a factory near Seattle. The fuselages are transported with the door assembly “semi-rigged” from Kansas to Washington, where Boeing finalizes the installation, ensuring the hull’s pressurization to 150% for proper functionality.

Fleet Impact and Grounding

With over 200 Boeing 737 MAX 9 planes delivered by Boeing, 171 of them feature a door plug panel instead of an emergency door. Following the FAA directive, Alaska Airlines grounded 18 of its MAX 9 planes, resulting in the cancellation of 163 flights. United Airlines, the other major U.S. carrier operating the MAX 9 with a door plug, also canceled 230 flights on Sunday, affecting 8% of its scheduled departures.

Other international carriers, including Copa Airlines, Aeromexico, and Turkish Airlines, have also grounded certain planes for inspection.

Official Responses

Boeing expressed regret over the incident and fully supported the FAA’s decision for immediate inspections. Alaska Airlines confirmed ongoing inspections on a quarter of its 737-9 fleet, emphasizing confidence in the aircraft’s safe return to service.

At a news conference, NTSB Chair Jennifer Homendy emphasized the seriousness of the incident, terming it an “accident, not an incident.” Homendy urged the public’s assistance in locating the missing door, believed to be in the west side of the Portland metro area near Oregon Route 217 and Barnes Road in the Cedar Mills suburb. The investigation is ongoing, with the NTSB emphasizing the fortunate outcome and potential psychological impact on passengers.

The aviation industry is closely monitoring developments as safety remains a top priority for regulators, manufacturers, and airlines worldwide.