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Boeing seeks FAA approval for higher production cap amid ongoing issues with max variants

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Boeing seeks FAA approval for higher production cap amid ongoing issues with max variants
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CEO Kelly Ortberg | Boeing

Boeing is seeking approval from the Federal Aviation Administration (FAA) to increase or remove the production cap on its 737 MAX series as it works toward certification of the aircraft’s longest variant, the MAX 10. The company expects design corrections addressing recent engine issues to be completed in the coming months.

The European Union Aviation Safety Agency (EASA) and FAA have directed Boeing to address problems involving engine overheating and thrust loss during extended taxiing. Another concern was identified when a bird strike could potentially trigger a load-reduction mechanism in the engine, leading to oil leaks and smoke entering the cabin.

Despite several setbacks that have delayed certification for years beyond initial projections, Boeing continues development efforts. The MAX 7 model was close to receiving a waiver that would have allowed production with deicing issues to be resolved post-delivery, similar to what has been permitted for the MAX 8 and 9 models. However, following a midair blowout incident involving an Alaska Airlines MAX 8 last year, quality control concerns led regulators to deny this waiver.

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Southwest Airlines plans for the MAX 7 to become its new mainline aircraft. Meanwhile, global interest remains high for the larger-capacity MAX 10, which over 1,200 customers have ordered as airlines seek more fuel-efficient narrowbody jets for major routes.

“We continue to mature the technical solutions for engine anti-ice and certification path for the 737 MAX family derivatives. Work on the solution is taking longer than expected, and we now are expecting certification in 2026,” said Boeing CEO Kelly Ortberg during a July earnings call reported by HeraldNet.

The anti-ice system defect affecting both short (MAX 7) and long (MAX 10) variants has delayed their certifications. In certain conditions, this flaw could cause overheating or failure of engine components. Boeing aims to complete redesigns next year while implementing interim risk-reduction measures through changes in equipment lists and flight manuals.

Additionally, if a CFM International LEAP-1B engine’s load-reduction device activates—such as after a bird strike—it may disrupt an oil line and allow burning oil smoke into ventilation systems. This presents serious safety risks that must be addressed before increasing production rates.

FAA oversight of Boeing’s manufacturing remains strict following two fatal crashes involving Lion Air and Ethiopian Airlines flights in recent years that killed hundreds of passengers. As Reuters reported in June 2025, Acting FAA Administrator Chris Rocheleau stated that inspectors would continue individual checks of both Dreamliner models and maintain limits on monthly output of the MAX series at 38 units while quality improvements are monitored (https://www.reuters.com/business/aerospace-defense/boeing-faa-max-production-cap-removal-2025-06).

Uncertified versions such as the MAX 7 and MAX 10 will not receive regulatory approval until all safety evaluations are complete and necessary corrections made. Delivery backlogs are growing due to these delays; many airlines now expect not to receive new MAX planes until at least 2027.

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