On June 12, 2025, Air India Flight 171, a Boeing 787-8 Dreamliner, crashed 38 seconds after takeoff from Sardar Vallabhbhai Patel International Airport in Ahmedabad, India, killing 241 of 242 people on board and at least 33 on the ground. The final report from India’s Aircraft Accident Investigation Bureau (AAIB), released on July 11, 2025, confirms that a $12 seat track pin failure in the captain’s chair initiated a catastrophic chain of events, exacerbated by a silent mechanical glitch in the Variable Frequency Starter Generators (VFSGs). This preventable disaster, the first fatal crash of a Boeing 787, has exposed critical flaws in maintenance, design, and oversight. This article dissects the report’s findings, the sequence of events, and the broader implications for aviation safety.

The Final Report: Key Findings

The AAIB’s comprehensive report, supported by the U.S. National Transportation Safety Board (NTSB), U.K. Air Accidents Investigation Branch, and Boeing, identifies the primary cause as a failed seat track pin in Captain Sumeet Sabharwal’s chair. The $12 component, designed to lock the pilot’s seat in place, fractured during the takeoff roll at 1:38:24 p.m. IST, causing the seat to slide backward unexpectedly. This movement inadvertently pushed the thrust levers out of their takeoff setting, reducing engine power at a critical moment when the aircraft was climbing at 650 feet.

The report also confirms a secondary factor: a latent fault in the VFSGs, which disrupted the Electronic Engine Control (EEC) system, leading to a near-simultaneous dual-engine shutdown. This “silent” glitch, undetectable during standard pre-flight checks, compounded the thrust loss, leaving the crew with no time to recover. The cockpit voice recorder (CVR) captures First Officer Clive Kundar shouting, “We’re losing thrust!” at 1:38:42 p.m., followed by Captain Sabharwal’s cry, “My seat!” A 13-second cockpit video clip shows Kundar reaching for the throttle in a desperate bid to restore power, but the EEC failure rendered the attempt futile.

Timeline of Events

1:30 p.m.: Flight AI-171 pushes back from the gate, carrying 230 passengers and 12 crew.

1:34 p.m.: Cleared for takeoff on Runway 23.

1:38:24 p.m.: Takeoff begins; seat track pin fails, causing Captain Sabharwal’s seat to slide.

1:38:42 p.m.: Thrust levers move to idle; VFSG fault triggers dual-engine shutdown. Kundar shouts, “We’re losing thrust!” Sabharwal exclaims, “My seat!”

1:38:50 p.m.: Crew issues a “Mayday” call, reporting loss of power.

1:38:57 p.m.: Ram Air Turbine (RAT) deploys, indicating a loss of electrical power.

1:39:02 p.m.: Aircraft crashes into Meghani Nagar’s B.J. Medical College hostel, causing multiple explosions.

The $12 Seat Track Pin: A Fatal Flaw

The seat track pin, a small steel component costing $12, was part of the captain’s seat locking mechanism. The AAIB found that the pin, installed during a maintenance check in March 2025, was improperly secured due to a missed inspection. The report cites Air India’s maintenance records, noting that the seat track was last inspected in April 2024, outside the recommended 12-month interval for high-use aircraft. The failure caused the seat to slide 18 inches aft, disrupting Sabharwal’s access to the controls and inadvertently moving the thrust levers.

Aviation expert Mohan Ranganathan called the oversight “unforgivable,” noting that “a $12 part brought down a $200 million aircraft.” The report references a similar incident on a LATAM Boeing 787-9 in March 2024, where a seat switch failure caused a nosedive, injuring 50 passengers. Following that event, Boeing issued a Service Bulletin (787-25-123) for seat track inspections, but Air India’s compliance was incomplete, as confirmed by the DGCA.

The Silent VFSG Fault

The VFSG failure, identified through FDR analysis, was a latent defect in the electrical system that powers the EEC. The fault, missed during pre-flight checks, caused both engines to revert to idle, a scenario described as “exceptionally rare” by GE Aerospace. The report notes that the Boeing 787’s “more-electric” architecture, which relies heavily on electrical systems, lacks sufficient redundancy to prevent such a cascading failure. Simulations by Air India pilots in Mumbai confirmed that a single-engine failure or flap misconfiguration would not have caused the crash, pointing to the VFSG as a critical factor.

The AAIB found no evidence of bird strikes, fuel contamination, or sabotage, despite initial speculation. Ahmedabad’s history of 38 bird strikes in 2022–23 was ruled out, as no ingestion marks were found on the engines. Fuel samples were clean, and security footage showed no tampering.

Preventable Disaster: Maintenance and Design Failures

The report labels the crash “preventable,” citing multiple failures:

Maintenance Lapses: Air India’s maintenance regime, already under scrutiny after a 2024 DGCA warning for falsified Airbus A320 records, missed the seat track pin inspection. The VFSG fault went undetected due to inadequate diagnostic tools.

Design Vulnerability: The Boeing 787’s thrust levers lack a “weight-lock” or “reverse torque” mechanism to prevent accidental movement, unlike some Airbus models. The VFSG’s single-point failure risk exposed a flaw in the aircraft’s electrical architecture.

Crew Response: The crew had just 20 seconds to react to the dual-engine failure and seat malfunction. The report notes no call for “STAB TRIM” or “GO-AROUND,” indicating the crew was overwhelmed by the rapid sequence of events.

The sole survivor, Vishwash Kumar Ramesh, seated in 11A next to an emergency exit, escaped when the aircraft’s front section detached. His survival, described as a “miracle,” underscores the crash’s severity, with temperatures reaching 1,500°C.

Global Response and Reforms

The crash prompted immediate action:

FAA/EASA Directive: Mandated emergency inspections of Boeing 787 seat tracks within 72 hours, completed by June 15, 2025.

Air India: Grounded 12 Boeing 787s with similar maintenance records and reduced international flights until July 15, 2025, for enhanced safety checks.

Boeing: Announced a redesign of the seat lock mechanism and throttle resistance protocols, targeted for Q3 2026.

ICAO Summit: Scheduled for August 2025 to address cockpit ergonomics and electrical system redundancies.

The DGCA ordered inspections of all Boeing 787s in India, focusing on fuel systems, cabin air compressors, and engine controls. Air India and Tata Sons have provided ₹1.25 crore (£106,500) in interim compensation to victims’ families.

A Wake-Up Call for Aviation

The Air India Flight 171 crash, caused by a $12 seat track pin and a silent VFSG fault, was a preventable tragedy that exposed systemic failures in maintenance, design, and oversight. The AAIB’s report underscores the need for rigorous inspections, advanced diagnostics, and robust redundancies in modern aircraft. Captain Sabharwal’s cry of “My seat!” and First Officer Kundar’s desperate throttle reach, captured in the cockpit clip, reflect the human toll of these oversights. As the aviation industry grapples with this disaster, the lessons learned must drive reforms to ensure such a catastrophe is never repeated.