A TEAM of Australian specialists will review the safety of Boeing's 787 Dreamliner after claims the plane could smash apart and emit toxic chemicals if it crashed.

A former Boeing engineer has warned the plane, which is made largely from brittle materials rather than flexible aluminium, was more likely to shatter on impact.

The carbon-composite material used in the plane's fuselage could also emit dangerous chemicals when burning, the engineer and other experts said.

The Civil Aviation Safety Authority today said the plane would not make it to Australia if it failed strict US safety reviews, and a team of safety specialists were standing by.

“The aircraft will be certified with the Federal Aviation Administration in the US, and of course, can’t enter commercial operations until that certification process is complete,” said CASA spokesman Peter Gibson.

“Once it has been certified it will then need to go through another review with each country’s airline that wishes to operate it," he said.

"We have assembled a team and been working precisely for this since early this year."

Qantas is set to become the world's biggest airline operator of the 787 Dreamliner, having ordered 65 planes with options to buy 20 more and rights on another 30.

But the aircraft will have to undergo severe scrutiny from both the CASA and Qantas engineers long before the first commercial passenger steps aboard.

“When the time comes for Qantas to introduce the new 787 Dreamliner to Australia, we the CASA have to access the certification of the aircraft and Qantas’ ability to operate the aircraft safely,” Mr Gibson said.

CASA's team of inspectors had spent time observing the construction of the plane and talking to Boeing's engineers in the US, he said.

David Cox of EGM Qantas Engineering said the airline's experts would also be testing the Dreamliner.

“All new aircraft go through a vast amount of testing and certification over many months, which is preceded by a testing program over many years,” he said.

“The issues raised have been part of the risk discussion we undertook with Boeing during the evaluation process for the aircraft.

“We are entirely comfortable with the 787's design and certification approval process.”

Concerns over the Dreamliner's safety were aired by former Boeing engineer Vince Weldon in an interview with journalist Dan Rather to be broadcast in the US tonight.

A spokesman for Boeing said Mr Weldon's claims were not valid and the materials used were safe.

"We've looked at Mr Weldon's claims. We've had technical committees review them. We do an exceptional amount of testing," a spokeswoman said.

"Absolutely, these materials are safe. They are tested (and) they will be certified."

News Limited

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Boeing 787 Dreamliner most successful in history

MORE than 50 of the world's airlines can't be wrong in their choice of Boeing's hi-tech Dreamliner ahead of the A380 "big bird" from Airbus.

The moulded carbon-fibre "plastic fantastic" has yet to fly but is already the most successful new airliner in aviation history.

Boeing's new-generation 787, otherwise known as the Dreamliner, is the biggest-selling new plane ever.

It has outsold its twin-deck European rival almost four to one; chalking up 750 orders worth $US114 billion ($125 billion) to Boeing.

While Qantas will use the 20 A380s it is buying to land growing passenger numbers through congested hubs such as Heathrow and Los Angeles, the Dreamliner will be the kangaroo carrier's workhorse.

The 65 it has ordered from Boeing will give it the flexibility it needs to grow its passenger loads by seeking less crowded destinations.

Instead of flying Melbourne-Los Angeles, Dreamliner passengers are likely to land at Dallas or Chicago.

The long-haul plane will fly up to 16,000km without refuelling, creating an opportunity for direct flights from Australia to Paris, Amsterdam and southern Europe in a plane that will be 20 per cent more fuel-efficient.

With the carbon composite much stronger than traditional aluminium, cabin pressure will be boosted to new and more comfortable levels.

Cabin noise has been reduced, and windows and lighting also have undergone radical changes.

The windows are 60 per cent bigger and passengers in aisle seats will get clear views outside.

Window shutters have been replaced with an electrochromic film that darkens electronically.

Outside light can be cut so you can sleep or watch a movie.

Other improvements include bigger toilets, increased head room, wider aisles and larger overhead bins.

I just visited the Boeing facility at Everett today.

Here are a couple of photos:

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This is the whole facility from construction

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to painting

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Here is a close-up of the dreamlifters:

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They are used only for transportation of fully-assembled aircraft parts (fuselage, wing, etc) from Europe. (Very coveted by UPS, etc, but only built for Beoing's own use)

And here is a comparison of the 747-400 and the 787-8. You can see that it is smaller than the 747, only one engine on each side. (with a whole lot more torque!) Notice, also, the curved wings.

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For more info, you can go to http://www.newairplane.com and click on the link "787 Dreamliner Site" or check out the Wikipedia article: http://en.wikipedia.org/wiki/Boeing_787-8

And here is one photo I forgot: they built this building ONLY for wining and dining new purchasers of their new planes.

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