What is the Boeing 737 MAX, and what does it succeed?

The Boeing 737 MAX is a series of narrow-body aircraft developed by Boeing Commercial Airplanes. It represents the fourth generation of the Boeing 737 and directly succeeds the Boeing 737 Next Generation.

What are the primary technical improvements incorporated into the Boeing 737 MAX?

The Boeing 737 MAX incorporates several key technical improvements, including more efficient CFM International LEAP engines, aerodynamic enhancements such as split-tip winglets, and structural modifications to the airframe.

When was the Boeing 737 MAX program officially announced, and when did its first flight take place?

The Boeing 737 MAX program was announced in August 2011, and the aircraft's first flight occurred on January 29, 2016.

Which regulatory body certified the Boeing 737 MAX in the U.S., and which airline received the first delivery?

The U.S. Federal Aviation Administration (FAA) certified the Boeing 737 MAX in March 2017. The first delivery, a MAX 8, was made to Malindo Air in May 2017.

What are the four main variants of the Boeing 737 MAX series, and which is the most widely ordered?

The four main variants of the 737 MAX series are the MAX 7, MAX 8, MAX 9, and MAX 10, which feature increasing fuselage length and seating capacity. The MAX 8 is the most widely ordered variant.

What is the typical passenger capacity and range of the Boeing 737 MAX aircraft?

The Boeing 737 MAX typically seats 138 to 204 passengers in a two-class configuration and has a range of 3,300 to 3,850 nautical miles (6,110 to 7,130 km; 3,800 to 4,430 mi).

As of July 2025, how many Boeing 737 MAX aircraft had been delivered, and how many additional orders were held?

As of July 2025, Boeing had delivered 1,923 aircraft and held orders for 4,856 more 737 MAX aircraft.

Which Boeing 737 MAX variants had not yet received FAA certification as of July 2025?

As of July 2025, the MAX 7 and MAX 10 variants had not yet received FAA certification, and the agency had not provided a timeline for their approval.

Who is considered the primary competitor of the Boeing 737 MAX family in the market?

The primary competitor of the Boeing 737 MAX family is the Airbus A320neo family, which occupies a similar market segment for narrow-body airliners.

What system was identified as a contributing factor in the 737 MAX crashes, and what was its underlying issue?

The Maneuvering Characteristics Augmentation System (MCAS) was linked to the crashes. It activated erroneously due to faulty angle of attack sensor data, causing uncommanded nose-down trim.

What were the significant consequences for Boeing following the 737 MAX incidents and grounding?

The incidents caused significant reputational and financial damage to Boeing, including billions of dollars in legal settlements, fines, and cancelled orders. The company was also charged with fraud in connection with the crashes.

When was the 737 MAX fleet globally grounded, and when was it cleared to return to service by the FAA?

The 737 MAX fleet was globally grounded from March 2019 to November 2020. The FAA lifted its grounding order on November 18, 2020, after modifications to flight control software and revised pilot training protocols.

What incident in January 2024 led to renewed scrutiny of the 737 MAX, and what was the cause?

In January 2024, a door plug detached mid-flight on Alaska Airlines Flight 1282, causing a rapid decompression. Investigations revealed that the four key bolts securing the door plug were not installed on delivery, as Boeing had opened the plug at its Renton factory to repair damaged rivets and failed to secure it properly.

What was Boeing's initial consideration for replacing the 737 in 2006?

In 2006, Boeing began considering replacing the 737 with a 'clean sheet' design, which is a completely new aircraft design rather than an updated version of an existing one, that could follow the Boeing 787 Dreamliner.

What event prompted Boeing to re-engine the 737, leading to the MAX program, instead of developing a completely new aircraft?

The launch of the fuel-efficient Airbus A320neo family by Boeing's competitor Airbus in December 2010, and a subsequent large order from American Airlines for both Airbus and re-engined Boeing jets, prompted Boeing to re-engine the 737.

What were the initial fuel efficiency targets for the re-engined 737 MAX upon its program launch?

Upon its launch, the re-engined 737 MAX was expected to burn 4% less fuel than its predecessor, with an initial reduction of 10-12% later enhanced to 14.5% to match or exceed the Airbus A320neo's 15% fuel-burn advantage.

Who was the launch customer for the Boeing 737 MAX program in 2011?

Southwest Airlines was signed up as the launch customer for the Boeing 737 MAX program in 2011.

When and where was the first 737 MAX aircraft, named Spirit of Renton, rolled out?

The first 737 MAX aircraft, a MAX 8 named Spirit of Renton, was rolled out at the Boeing Renton Factory on December 8, 2015.

What percentage of the 737 airframe is supplied by Spirit AeroSystems, and what components does it include?

Spirit AeroSystems supplies 69% of the 737 airframe, including the fuselage, thrust reverser, engine pylons, nacelles, and wing leading edges.

What automated technologies were implemented to increase the production rate of the 737 MAX?

A new spar-assembly line with robotic drilling machines and the Electroimpact automated panel assembly line were implemented, expected to increase throughput by 33% and speed up wing lower-skin assembly by 35%, respectively.

Where did Boeing establish its first 737 completion and delivery facility outside the United States?

Boeing established its first 737 completion and delivery facility outside the United States in Zhoushan, China, through a collaboration with Comac (Commercial Aircraft Corporation of China).

How did the 737 MAX gain its airworthiness approval, and what was a criticism of this process?

The 737 MAX gained its airworthiness approval based on the 737 legacy series as a Supplemental Type Certificate (STC), rather than a new design approval. A criticism was that the FAA delegated many evaluations to Boeing, allowing the manufacturer to review its own product and potentially expediting approval.

What manufacturing quality issue with the LEAP-1B engines led to a temporary suspension of 737 MAX flights in May 2017?

CFM International notified Boeing of a possible manufacturing quality issue with low pressure turbine (LPT) discs in LEAP-1B engines, leading to a temporary suspension of 737 MAX flights on May 4, 2017.

Which airline was the second to put a 737 MAX into service, and what notable flight did it perform?

Norwegian Air International was the second airline to put a 737 MAX into service, performing its first transatlantic flight with a MAX 8 on July 15, 2017, between Edinburgh Airport in Scotland and Bradley International Airport in the U.S. state of Connecticut.

What was the initial response of the U.S. FAA to the 737 MAX crashes, and how did it differ from other air authorities?

The U.S. FAA was one of the last air authorities to ground the aircraft, initially defending against groundings by issuing a Continued Airworthiness Notice on March 11, 2019, before finally grounding it on March 13, 2019. China was the first to ground the aircraft the day after the second crash.

How was the Maneuvering Characteristics Augmentation System (MCAS) redesigned after the fatal crashes?

The MCAS was redesigned to address the single point of failure by using data from both of the aircraft's angle-of-attack (AoA) sensors, instead of just one, to prevent erroneous activations.

What was a significant finding regarding pilot training related to MCAS before the Lion Air Flight 610 crash?

Before the Lion Air Flight 610 crash, pilots were not informed by Boeing of the existence of MCAS and were not required to undergo simulator training on the differences between the 737 MAX and earlier 737 versions.

What financial penalties and compensation did Boeing agree to pay in connection with the 737 MAX fraud conspiracy charges?

Boeing settled by paying over US$2.5 billion in penalties and compensation, which included a criminal monetary penalty of $243.6 million, $1.77 billion in damages to airline customers, and $500 million to a fund for the families of crash victims.

Why did Boeing suspend 737 MAX production from January 2020?

Boeing suspended 737 MAX production from January 2020 to conserve funds and prioritize the delivery of stored aircraft, as the recertification process extended into 2020.

Which airline was the first to resume regular passenger service with the 737 MAX after its ungrounding?

The Brazilian low-cost carrier Gol was the first airline to resume regular passenger service with the 737 MAX on December 9, 2020.

What role does Tata Advanced Systems (TASL) play in the 737's supply chain?

In 2021, Tata Advanced Systems (TASL) joined the 737's supply chain by opening a new production line to produce the fuselage of Boeing AH-64 Apache, and in 2023, Tata Boeing Aerospace Limited (TBAL) shipped the first vertical fin structure for the Boeing 737 aircraft.

What was the FAA's response to Boeing's plan for a fourth 737 MAX production line after the Alaska Airlines Flight 1282 accident?

After the Alaska Airlines Flight 1282 accident, the FAA announced it would not grant any production expansion of the 737 MAX until it is satisfied that more stringent quality control measures have been enacted, impacting Boeing's plan for a fourth production line at the Boeing Everett Factory.

What new safety requirement from the U.S. Aircraft Safety and Certification Reform Act of 2020 affected the certification of the MAX 7 and MAX 10?

The U.S. Aircraft Safety and Certification Reform Act of 2020 requires airliners to be fitted with an engine-indicating and crew-alerting system (EICAS) if type certificated after December 31, 2022, which affected the MAX 7 and MAX 10.

What compromise did the U.S. Congress reach in December 2022 regarding the MAX 7 and MAX 10 certification?

The U.S. Congress agreed to allow Boeing to certify the MAX 7 and MAX 10 without EICAS, but required the company to install a third angle-of-attack sensor in all 737 MAX types and a switch to disable the stick shaker, with these changes to be retrofitted to all delivered 737 MAXs within three years of MAX 10 certification.

What safety issue related to the engine anti-ice system affected all MAX variants, and what was Boeing's initial request for the MAX 7?

Boeing found that if the engine anti-ice system was left running after icing was no longer an issue, it could heat the carbon composite inlet of the nacelle, causing it to break and fall off, potentially damaging the engine or fuselage. Boeing initially requested an exemption for the MAX 7 from correcting this issue before entry into service.

How have major airlines reacted to the ongoing delays in the certification of the MAX 7 and MAX 10?

Major carriers like Southwest Airlines and United Airlines have been impacted. Southwest removed the MAX 7 from its 2024 fleet planning but remains committed to the type, while United expressed disappointment, removed the MAX 10 from its future fleet planning, and initiated discussions with Airbus for A321neos.

What was a primary design objective for the 737 MAX in mid-2011 regarding fuel efficiency, and what reduction was achieved?

A primary design objective in mid-2011 was to match the fuel burn of the 737 MAX to the Airbus A320neo's 15% fuel-burn advantage. The 737 MAX ultimately achieved a 14.5% fuel consumption reduction from the 737 Next Generation.

How did Boeing modify the engine placement and fan size on the 737 MAX, and what aerodynamic consequence did this have?

The engine fan was widened from 61 inches to 69.4 inches, necessitating raising the nose gear and placing the engine higher and further forward on the wing. This modified mounting arrangement changed the aerodynamic characteristics, leading to a pitch-up tendency that required the development of MCAS.

What is the function of the split-tip winglet on the 737 MAX?

The split-tip winglet on the 737 MAX is designed to reduce vortex drag, which in turn improves fuel efficiency, while ensuring the aircraft remains compatible with ICAO aerodrome reference code C gates, similar to existing Boeing 737s.

What type of displays are featured in the Boeing 737 MAX cockpit, and what is their size?

The Boeing 737 MAX cockpit features four 15.1-inch (380 mm) liquid-crystal displays (LCDs), supplied by Rockwell Collins, which are similar to those used on the 787 Dreamliner.

What is the name of the engine used on the Boeing 737 MAX, and what is its fan diameter?

The engine used on the Boeing 737 MAX is the CFM International LEAP-1B, which has a fan diameter of 69.4 inches (176 cm).

What is the bypass ratio of the CFM LEAP-1B engine, and how does it contribute to noise reduction?

The CFM LEAP-1B engine has a 9:1 bypass ratio, which is an increase from the previous CFM56 engine. This higher bypass ratio, along with features like chevrons on the nacelle, contributes to a 40% smaller noise footprint.

What was the dependability rate of the 737 MAX after its first year of service?

After one year of service, the 737 MAX achieved a dependability rate of 99.4%.

What was the estimated operating margin for each 737 MAX 8 at its list price in 2019, and how did this change after the crashes?

In 2019, Moody's estimated the operating margin for each 737 MAX 8 at its list price of $121.6 million to be US$12-15 million. However, this margin was significantly reduced due to rising costs following the two crashes, the FAA grounding, and severe production disruption.

What are the official FAA type certificate and marketing designations for the 737 MAX 7, MAX 8, and MAX 9 since 2020?

Since 2020, the official FAA type certificate and marketing designations for the 737 MAX 7, MAX 8, and MAX 9 have been 737-7, 737-8, and 737-9, respectively.

How does the redesigned 737 MAX 7 differ physically from the 737-700?

Compared to the 737-700, the redesigned MAX 7 features a pair of over-wing exit doors instead of a single door, a 46-inch (120 cm) longer aft fuselage, and a 30-inch (76 cm) longer forward fuselage, along with structural re-gauging and strengthening.

What is the maximum passenger capacity of the 737 MAX 200 in a single-class high-density configuration, and why does it require extra exit doors?

The 737 MAX 200 can seat up to 200 passengers in a single-class high-density configuration. It requires an extra pair of exit doors due to this higher passenger capacity, as mandated by safety regulations.

Who was the launch customer for the high-density 737 MAX 200 variant?

Ryanair was the launch customer for the high-density 737 MAX 200 variant, with an order for 100 aircraft finalized in December 2014.

What was the primary motivation behind the development of the 737 MAX 10?

The primary motivation for developing the 737 MAX 10 was to compete with the Airbus A321neo, which had significantly outsold the MAX 9, and to meet the demands of loyal Boeing customers like Korean Air and United Airlines for a larger variant.

The Boeing 737 MAX: An Engineering Odyssey and its Unforeseen Challenges

Delving into the design, development, and critical incidents that reshaped modern aviation safety standards for this prominent narrow-body airliner.

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Overview

A New Generation of Flight

The Boeing 737 MAX represents the fourth generation of Boeing's highly successful 737 narrow-body aircraft series. Conceived as a successor to the 737 Next Generation, its primary objective was to enhance fuel efficiency and operational performance through significant engineering advancements. These include the integration of advanced CFM International LEAP engines, innovative split-tip winglets for improved aerodynamics, and various structural modifications designed to optimize its capabilities.^[1]

Key Milestones

The program was officially announced in August 2011, marking a pivotal moment in Boeing's strategy to maintain its competitive edge in the single-aisle market. The maiden flight of the 737 MAX occurred in January 2016, followed by its certification by the U.S. Federal Aviation Administration (FAA) in March 2017. The first MAX 8 was delivered to Malindo Air in May 2017, swiftly entering commercial service.^[4]^[5]

Unforeseen Challenges

Despite its promising launch, the 737 MAX faced unprecedented scrutiny following two fatal accidents in late 2018 and early 2019. These incidents led to a global grounding of the entire fleet, a measure that had profound implications for aviation safety, regulatory oversight, and Boeing's corporate standing. Subsequent investigations highlighted critical issues related to the Maneuvering Characteristics Augmentation System (MCAS) and the aircraft's certification process, necessitating extensive modifications and revised pilot training protocols before its eventual return to service.^[62]^[63]

Development

Strategic Genesis

Boeing's journey towards the 737 MAX began in 2006 with considerations for a "clean sheet" replacement for the 737, a design philosophy that would follow the innovative Boeing 787 Dreamliner. However, this decision was postponed, and the landscape shifted dramatically in December 2010 when Airbus launched its A320neo family, boasting superior fuel economy and operational efficiency. This competitive pressure, coupled with a significant order from American Airlines (a long-standing Boeing customer) that included A320neos, compelled Boeing to pivot towards re-engining the 737 rather than pursuing an entirely new design.^[6]^[7]^[8]^[13]^[14]^[15]

Program Launch & Production

The re-engined 737 MAX program was officially approved in August 2011, with a commitment to surpass the A320neo's range and achieve a 4% reduction in fuel burn, later enhanced to 14.5% compared to the 737NG. This involved extensive studies for drag reduction and structural modifications. The development cost was estimated to be in the billions, with Southwest Airlines securing the role of launch customer in 2011.^[16]^[17]^[18]

Production commenced with the first fuselage assembly in August 2015, leading to the roll-out of the first 737 MAX 8, named Spirit of Renton, in December 2015. The production process involved key suppliers like Spirit AeroSystems for airframe components and CFM International for engines. Boeing aimed for ambitious production rate increases, which, at times, strained the supply chain, leading to delays in engine and fuselage deliveries. A significant development was the collaboration with Comac to establish a completion and delivery facility in Zhoushan, China, marking Boeing's first such facility outside the United States.^[28]^[29]^[32]^[36]^[38]

Testing & Certification

The 737 MAX received its airworthiness approval as a Supplemental Type Certificate (STC) based on the existing 737 legacy series, rather than a new design approval. This approach aimed to streamline the certification process. The first flight of the MAX 8 occurred on January 29, 2016. Extensive flight testing followed, covering aerodynamics, stability, control, performance, and systems. The MAX 8 achieved FAA certification on March 8, 2017, and EASA approval later that month.^[43]^[44]^[45]

However, the certification process later drew criticism for the FAA's delegation of many evaluations to Boeing, and reports suggested Boeing pushed to expedite approval to compete with the A320neo. These factors would become central to the investigations following the subsequent accidents.^[47]^[54]^[55]

Design

Aerodynamic Innovations

A core design objective for the 737 MAX was to significantly improve fuel efficiency. This was achieved through several aerodynamic enhancements:

Larger Fan Diameter: The engine fan was expanded from 61 inches to 69.4 inches, necessitating a higher and more forward placement of the engines on the wing and a taller nose gear strut to maintain ground clearance.^[133]^[144]
Split-Tip Winglets: These distinctive winglets were designed to reduce vortex drag, thereby enhancing fuel efficiency while ensuring the aircraft could still operate within existing ICAO aerodrome reference code C gates.^[134]
Refined Tail Cone & APU: A re-contoured tail cone and revised auxiliary power unit (APU) inlet and exhaust contributed to further drag reduction.^[23]

Maneuvering Characteristics Augmentation System (MCAS)

The repositioning of the larger engines on the wing altered the aircraft's aerodynamic characteristics, introducing a tendency for the nose to pitch up at high angles of attack. To counteract this and maintain handling commonality with previous 737 models (a critical factor for minimizing pilot retraining), Boeing developed the Maneuvering Characteristics Augmentation System (MCAS). This software-based flight control law was designed to automatically apply nose-down trim to the horizontal stabilizer when specific conditions were met. Critically, MCAS was designed with greater authority than the traditional Speed Trim System (STS) and, in its initial design, could not be easily disengaged by pilots using standard column cutout switches, a factor that proved catastrophic in the subsequent accidents.^[136]^[139]^[140]

Structural & Cockpit Evolution

To accommodate the heavier, larger engines and maintain structural integrity, the 737 MAX underwent several structural reinforcements. This included a taller nose-gear strut, strengthened main landing gear and supporting structures, and thicker fuselage skins in certain areas, adding approximately 6,500 pounds to the MAX 8's empty weight. The maximum takeoff weight was also increased to preserve fuel and payload capacity.^[23]

The cockpit retained a high degree of commonality with the 737 Next Generation to facilitate pilot transitions. However, it incorporated modern advancements such as four 15.1-inch liquid-crystal displays (LCDs) from Rockwell Collins, similar to those found in the 787, to enhance situational awareness. While most systems were carried over, the extended spoilers were fly-by-wire controlled, representing a subtle but significant technological update.^[33]^[137]^[138]

Powerplant: CFM LEAP-1B

The heart of the 737 MAX's efficiency improvements lies in its CFM LEAP-1B engines. These engines offered a 10-12% initial efficiency gain over the previous CFM56 engines. Key features include an 18-blade carbon-fiber fan, enabling a significantly higher bypass ratio of 9:1 (compared to 5.1:1 in the CFM56), which dramatically reduced the noise footprint. The engine's advanced two-spool design, higher overall pressure ratio (41:1 from 28:1), and use of advanced hot-section materials contributed to a 15% reduction in thrust-specific fuel consumption (TSFC) and lower emissions. Each LEAP-1B engine weighs approximately 849 pounds more than its predecessor, a factor influencing the aircraft's structural and aerodynamic design.^[18]^[23]^[143]

Variants

The MAX Family

The Boeing 737 MAX series comprises several variants, each designed to cater to different market segments and capacity requirements. These include the MAX 7, MAX 8, MAX 9, and MAX 10, which directly succeed the 737-700, -800, and -900ER models, respectively. Additionally, a high-density version, the MAX 8-200, and business jet configurations (BBJ MAX) have been developed. The MAX 8 is the most widely ordered variant, reflecting its broad appeal in the narrow-body market.^[157]^[162]

737 MAX 7

Basis: Originally based on the 737-700, redesigned to accommodate 138 seats (two more rows).
Structural Changes: Features a 46-inch longer aft fuselage and a 30-inch longer forward fuselage, along with structural strengthening. Uses the same wing and landing gear as the MAX 8.
Performance: Expected to fly 1,000 nautical miles farther than the -700 with 18% lower fuel costs per seat. Boeing projected 7% lower operating costs per seat compared to the A319neo.
Status: First flight in March 2018. Entry into service has been repeatedly delayed, impacting major customers like Southwest Airlines, partly due to safety issues with the engine anti-ice system. Certification is now anticipated in 2026.^[164]^[165]^[166]^[167]^[168]^[169]^[170]^[171]^[172]^[173]^[174]^[175]^[176]^[177]^[178]

737 MAX 8

Role: Replaces the 737-800, featuring a longer fuselage than the MAX 7.
Performance: Initial range of 3,515 nautical miles, planned to increase to 3,610 nautical miles. It boasts a lower empty weight and higher maximum takeoff weight compared to the Airbus A320neo.
Operational History: First commercial flight by Malindo Air in May 2017. Successfully completed high-altitude test flights in La Paz, Bolivia. Valued at approximately $52.85 million in early 2017.^[23]^[180]^[181]^[182]^[183]

737 MAX 200

Description: A high-density version of the 737 MAX 8, designed to seat up to 200 passengers in a single-class configuration.
Key Feature: Requires an extra pair of exit doors due to its higher passenger capacity.
Economics: Boeing projected it to be 20% more cost-efficient per seat than current 737 models and 5% lower operating costs than the standard 737 MAX 8.
Status: Launched with Ryanair's order in September 2014. Certified by the FAA in March 2021, with Ryanair taking first delivery in June 2021.^[160]^[184]^[185]^[186]^[187]^[188]^[189]^[190]^[191]^[192]^[193]^[194]^[195]^[196]

737 MAX 9

Role: Replaces the 737-900, with a longer fuselage than the MAX 8.
Performance: Initial range of 3,510 nautical miles, planned to increase to 3,605 nautical miles.
Operational History: Lion Air was the launch customer. Rolled out in March 2017, with its first flight in April 2017. Certified by February 2018, and first delivered to Thai Lion Air in March 2018.^[33]^[48]^[159]^[180]^[197]^[198]^[199]^[200]^[201]

737 MAX 10

Development: Developed in response to customer demand (e.g., Korean Air, United Airlines) to compete with the Airbus A321neo.
Design: Features a modest stretch of 66 inches, enabling seating for up to 230 in a single class or 189 in a two-class configuration. It retains the existing wing and LEAP 1B engine from the MAX 9, with a trailing-link main landing gear as the primary structural modification.
Performance: Range of 3,100 nautical miles, slightly less than the MAX 9. Boeing projects 5% lower trip and seat costs compared to the A321neo.
Status: Launched in June 2017 with significant orders from United Airlines. First flight in June 2021. Certification has faced delays, now expected in 2026, impacting major customers like United and Delta, partly due to the engine anti-ice system and stall management yaw damper (SMYD) system issues.^[121]^[122]^[123]^[124]^[125]^[126]^[127]^[128]^[129]^[130]^[131]^[132]^[202]^[203]^[204]^[205]^[206]^[207]^[208]^[209]^[210]^[211]^[212]^[213]^[214]^[215]^[216]^[217]^[218]^[219]^[220]^[221]^[222]^[223]^[224]^[225]^[226]^[227]^[228]

Boeing Business Jet (BBJ) MAX

Description: Business jet variants of the 737 MAX 7, 8, and 9.
Features: Incorporate the new CFM LEAP-1B engines and advanced winglets, offering 13% better fuel burn than the original Boeing Business Jet.
Range: BBJ MAX 8 has a range of 6,325 nautical miles, BBJ MAX 9 a 6,255 nautical miles range, and the BBJ MAX 7 boasts a 7,000 nautical miles range with 10% lower operating costs than the original BBJ.^[229]^[230]^[231]

Incidents

The Grounding Crisis

The operational history of the Boeing 737 MAX is indelibly marked by two catastrophic accidents: Lion Air Flight 610 in October 2018 and Ethiopian Airlines Flight 302 in March 2019. These incidents, occurring within five months of each other, resulted in the tragic loss of 346 lives and led to an unprecedented global grounding of the entire 737 MAX fleet from March 2019 to November 2020.^[61]^[249]

Investigations into both crashes revealed a critical common factor: the Maneuvering Characteristics Augmentation System (MCAS). This system, designed to automatically push the aircraft's nose down, activated erroneously due to faulty angle of attack (AoA) sensor data. A significant finding was Boeing's failure to adequately disclose MCAS to operators and the lack of required simulator training for pilots on the system's differences from earlier 737 versions. Furthermore, shortcomings in the FAA's certification process for the aircraft were identified, suggesting a systemic breakdown in oversight.^[47]^[62]^[63]^[64]^[65]^[66]^[67]^[68]^[69]^[70]

Recertification & Aftermath

During the 20-month grounding, Boeing undertook a significant redesign of the MCAS computer architecture, ensuring data from both AoA sensors would be used and requiring simulator training for pilots. The FAA, along with other global aviation authorities like Transport Canada and EASA, conducted independent recertification flights and imposed additional requirements. The grounding had severe financial repercussions for Boeing, including billions in legal settlements, fines, and canceled orders. Production was temporarily halted and then slowly ramped up, with a focus on clearing the backlog of undelivered aircraft.^[71]^[72]^[73]^[74]^[75]^[76]^[77]^[78]^[79]^[80]^[81]^[82]^[83]^[84]^[85]^[86]^[87]^[88]^[89]^[90]^[91]^[92]^[93]^[94]^[95]^[96]^[97]^[98]^[99]^[100]^[101]^[102]^[103]^[104]^[105]^[106]^[107]^[108]^[109]^[110]^[111]^[112]^[113]^[114]^[115]^[116]^[117]^[118]^[119]^[120]

Alaska Airlines Flight 1282

In January 2024, a new incident brought the 737 MAX 9 under renewed scrutiny. Alaska Airlines Flight 1282 experienced an uncontrolled decompression shortly after takeoff from Portland International Airport when a mid-cabin exit door plug detached. This particular MAX 9 variant, configured for lower passenger density, had these doors replaced with plugs. While there were no fatalities or serious injuries, the incident raised significant concerns about Boeing's production quality and safety practices. Investigations revealed that four key bolts intended to secure the door plug were not installed during manufacturing at Boeing's Renton factory. This led to a temporary grounding of affected MAX 9 aircraft and intensified regulatory oversight on Boeing's manufacturing processes.^[260]^[261]^[262]^[263]^[264]^[265]^[266]^[267]

Southwest Airlines Flight 746

In May 2024, another incident involving a 737 MAX 8 operated by Southwest Airlines Flight 746 from Phoenix to Oakland prompted further investigation by U.S. authorities. The aircraft experienced a "Dutch roll," a complex aerodynamic oscillation involving yaw and roll. Subsequent inspections revealed damage to the rudder standby power control unit, highlighting ongoing concerns regarding the aircraft's control systems and manufacturing integrity.^[268]^[269]

Specifications

The following table provides a detailed overview of the key characteristics and performance metrics for the various Boeing 737 MAX variants, offering a comparative analysis of their design and operational capabilities.

737 MAX Characteristics^[270]
Variant	737 MAX 7	737 MAX 8^[271]	737 MAX 9	737 MAX 10
Cockpit crew	Two
Typical seating	153 (8J + 145Y)	178 (12J + 166Y)	193 (16J + 177Y)	204 (16J + 188Y)
Maximum seats^[272]	172	189^[273] or 210^[274]	220	230
Seat pitch	28–29 in (71–74 cm) in high density, 29–30 in (74–76 cm) in economy, 36 in (91 cm) in business
Cargo capacity	1,139 cu ft (32.3 m³)	1,540 cu ft (44 m³)	1,811 cu ft (51.3 m³)	1,961 cu ft (55.5 m³)
Length	116 ft 8 in (35.56 m)	129 ft 6 in (39.47 m)	138 ft 4 in (42.16 m)	143 ft 8 in (43.79 m)
Wing	117 ft 10 in (35.92 m) span, 1,370 sq ft (127 m²) area^[49]
Overall height^[275]	40 ft 4 in (12.29 m)
Maximum takeoff weight (MTOW)	177,000 lb (80,000 kg)	182,200 lb (82,600 kg)	194,700 lb (88,300 kg)	197,900 lb (89,800 kg)
Fuel capacity	6,820 US gal (25,800 L) – 45,694 lb (20,726 kg) (no ACT)^[276]
Engine (× 2)	CFM International LEAP-1B, 69.4 in (176 cm) fan diameter,^[277] 26,786–29,317 lbf (119–130 kN)^[49]
Cruising speed	Mach 0.79 (453 kn; 839 km/h; 521 mph)^[278]
Range^[279]	3,800 nmi (7,000 km; 4,400 mi)	3,500 nmi (6,500 km; 4,000 mi)^[280]	3,300 nmi (6,100 km; 3,800 mi)	3,100 nmi (5,700 km; 3,600 mi)
Ceiling	41,000 ft (12,000 m)^[49]
Takeoff (SL, ISA, MTOW)	7,000 ft (2,100 m)	8,300 ft (2,500 m)	8,500 ft (2,600 m)
Landing (SL, MLW, dry)	5,000 ft (1,500 m)	5,000 ft (1,500 m)	5,500 ft (1,700 m)
ICAO Type^[281]	B37M	B38M	B39M	B3XM

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References

In 2019, there were 47 orders, but 183 cancellations of 737 MAX.[247]

In 2020, there were 112 orders, but 641 cancellations of 737 MAX.[248]

In 2021, there were 749 orders, but 374 cancellations of 737 MAX.[1]

MAX 200: 2,700 nmi (5,000 km; 3,100 mi)[277]

Production halted between January and late May 2020[2]

A full list of references for this article are available at the Boeing 737 MAX Wikipedia page

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The Boeing 737 MAX: An Engineering Odyssey and its Unforeseen Challenges

💡 Dive in with Flashcard Learning! 💡

Overview ✈️

🚀 A New Generation of Flight

🗓️ Key Milestones

📉 Unforeseen Challenges

Development 🛠️

💡 Strategic Genesis

📈 Program Launch & Production

✅ Testing & Certification

Design 📐

💨 Aerodynamic Innovations

🧠 Maneuvering Characteristics Augmentation System (MCAS)

🏗️ Structural & Cockpit Evolution

⚙️ Powerplant: CFM LEAP-1B

Variants 🔀

📏 The MAX Family

737 MAX 7

737 MAX 8

737 MAX 200

737 MAX 9

737 MAX 10

Boeing Business Jet (BBJ) MAX

Incidents 🚨

墜 The Grounding Crisis

🔄 Recertification & Aftermath

🚪 Alaska Airlines Flight 1282

🌀 Southwest Airlines Flight 746

Specifications 📋

Teacher's Corner 🧑‍🏫

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True or False? 🤔

❓ Test Your Knowledge! ❓

Gamer's Corner 🎮

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Explore More Topics

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References

📜 References

Feedback & Support 👍

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Disclaimer ⚠️

📜 Important Notice

Dive in with Flashcard Learning!

Overview

A New Generation of Flight

Key Milestones

Unforeseen Challenges

Development

Strategic Genesis

Program Launch & Production

Testing & Certification

Design

Aerodynamic Innovations

Maneuvering Characteristics Augmentation System (MCAS)

Structural & Cockpit Evolution

Powerplant: CFM LEAP-1B

Variants

The MAX Family

Incidents

The Grounding Crisis

Recertification & Aftermath

Alaska Airlines Flight 1282

Southwest Airlines Flight 746

Specifications

Teacher's Corner

True or False?

Test Your Knowledge!

Gamer's Corner

Discover other topics to study!

References

Feedback & Support

Disclaimer

Important Notice