U.S. and European regulators have mandated urgent inspections of certain Boeing 757 aircraft following the discovery of structural cracks in areas associated with a specific winglet modification. The directive targets aircraft equipped with Aviation Partners Boeing’s scimitar blended winglets (SBW), requiring operators to carry out detailed checks within a very short timeframe.
The Federal Aviation Administration (FAA) issued an immediately effective airworthiness directive on Feb. 26, giving operators five days to perform high-frequency eddy current inspections of the affected areas. The following day, the EASA adopted the same measure, extending the requirement to European operators.
The regulatory action was prompted by the discovery of a crack on a Boeing 757-200 during a heavy maintenance visit. The crack was located on the outer lower wing skin, near the access panel installed as part of the Aviation Partners Boeing winglet modification. Until now, this panel had not been subject to a mandatory inspection requirement.
After the initial finding, the modification provider issued a service bulletin in early February recommending inspections within 30 days. However, additional reports of similar cracks soon followed, leading regulators to significantly shorten the compliance window. According to available information, cracks have been confirmed on five aircraft to date.
The FAA directive affects 156 U.S.-registered Boeing 757s. Fleet data indicate that more than 250 Boeing 757 aircraft worldwide are equipped with winglets, including some currently in storage, although not all feature the SBW configuration targeted by the directive.
The scimitar blended winglet was introduced in 2015, with United Airlines placing the launch order. The upgrade replaces the standard aluminum winglet tip with a scimitar-shaped cap designed to further reduce drag and improve fuel efficiency. Supplemental type certificates for the modification were granted in 2016.
The swift and coordinated response by U.S. and European authorities underscores the industry’s cautious approach to structural findings, particularly those involving critical wing components that may affect long-term airworthiness and operational safety. Operators are now required to complete the inspections promptly and address any damage identified.
