Federal investigators have uncovered alarming evidence connecting a fatal cargo plane crash in Kentucky to a structural deficiency previously identified by Boeing over a decade earlier. The November incident involved a UPS-operated MD-11F freighter that erupted in flames after experiencing catastrophic engine separation during takeoff from Louisville International Airport.
According to the National Transportation Safety Board’s (NTSB) latest investigative update, the aircraft briefly became airborne before veering uncontrollably into an industrial zone. The tragedy claimed fifteen lives—three flight crew members and twelve individuals on the ground.
The investigation has pinpointed fatigue cracks within the engine mounting assembly as the primary failure point. These fractures, resulting from repeated stress on a critical bearing component, mirror incidents documented by Boeing in 2011. At that time, the aerospace manufacturer issued a non-binding service letter to operators acknowledging identical part failures across four instances involving three different aircraft.
Despite this recognition, Boeing’s internal assessment concluded the issue ‘would not result in a safety of flight condition.’ The company recommended voluntary visual inspections at five-year intervals and proposed optional component upgrades, neither of which were mandated.
Aviation safety expert Tim Atkinson, a former accident investigator, expressed grave concerns regarding Boeing’s judgment. ‘The structure concerned is not decorative—it’s an essential part of the mechanism that attaches the engine to the wing and carries loads such as thrust and drag,’ Atkinson stated. ‘It’s extraordinary that Boeing concluded that a failure of this part would not have safety consequences.’
This incident renews scrutiny of Boeing’s safety protocols, echoing criticisms from recent 737 Max controversies and manufacturing quality issues. The company extended condolences to affected families while pledging continued cooperation with the ongoing NTSB investigation. A final determination regarding the crash’s cause awaits the agency’s comprehensive report.