Boeing launched the 787 Dreamliner in April 2004 with a record order for 50 aircraft from All Nippon Airways. The plan was to open thin long-haul routes rather than funnel everyone through hubs in A380-style giants. Boeing also spread the supply chain worldwide and built the airframe mainly from carbon fiber. Both were bold departures from Boeing's usual way of working, and both carried real risk.
The pain came quickly. The 787-8 first flew on December 15, 2009, over two years late, and ANA began service on October 26, 2011. Lithium-ion battery fires then grounded the world fleet for more than three months in 2013, the first grounding of an airliner type since 1979. Boeing redesigned the battery box and vented any smoke overboard. The fleet returned to the air a few months later.
Once the fix was approved, the -8 settled in as a long-range route opener. Airlines flew thin city pairs, such as secondary European cities to distant hubs, that could never fill a 777. Around 400 were built before the larger -9 and -10 took over new sales. The wider program has passed 1,100 deliveries and two billion passengers. ANA, Japan Airlines, American and Qatar Airways all fly it.