On 22 October, Boeing celebrated a significant milestone for its 777 Freighter, announcing that the aircraft had overtaken the iconic 747 to become the world’s most widely operated widebody freighter. However, behind the manufacturer’s latest achievement lies a considerable production problem. According to a Reuters investigation published just one day later, manufacturing of the Boeing 777F has been stalled for nearly two months following a dispute with a critical parts supplier.
The disruption centres on Vaero, a Florida-based aerospace supplier responsible for manufacturing trailing-edge rib kits used in the wings of Boeing’s 777 Freighter and 767 aircraft. Boeing identified the company as its sole supplier of these components, meaning that the interruption of deliveries left the manufacturer without an immediate alternative source.
In August, Boeing filed a legal complaint alleging that Vaero had stopped supplying the required components amid a pricing dispute. The resulting shortage disrupted wing production at Boeing’s Everett facility in Washington, preventing assembly work from progressing as planned. According to the court filings reviewed by Reuters, Boeing estimated that the interruption could cost the company as much as $6.5 million per day.
Although the two companies reached a settlement in late September, the production difficulties have persisted. Three Boeing employees familiar with the situation told Reuters that manufacturing of the 777F had still not resumed as of 23 October, nearly a month after the agreement was reached.
The consequences have already become visible on Boeing’s final assembly line. According to one employee, two partially assembled 777 Freighters were removed from the production line because of the missing components. Reuters, using information from aviation consultancy IBA, identified one of these aircraft as destined for FedEx.
The shortage has also extended beyond the 777 programme, affecting production of the Boeing 767 Freighter and its military counterpart, the KC-46 Pegasus aerial refuelling tanker. However, the situation appears to have improved somewhat for the 767, with at least some components reportedly arriving following the September settlement.
Boeing Looks to Reduce Its Dependence on Vaero
With production still disrupted, Boeing is reportedly exploring the possibility of manufacturing the affected components internally. Two people familiar with the matter told Reuters that the manufacturer was seeking to bring production of the trailing-edge rib kits in-house, potentially reducing its dependence on Vaero.
The disruption does not affect Boeing’s next-generation 777X programme, which uses a different wing design constructed from composite materials.
Nevertheless, the interruption comes at an important time for Boeing’s freighter business. The manufacturer has delivered 21 Boeing 777 Freighters during 2026, while its existing global fleet has grown to more than 330 aircraft. Boeing estimates that the type now accounts for approximately 40% of global freighter capacity.
Further deliveries may still take place before the end of the year, as several aircraft reportedly had their wings completed before the supply interruption began. Consequently, the production stoppage does not necessarily mean that all remaining 2026 deliveries have been suspended.
Boeing declined to comment on the situation when approached by Reuters, while Vaero did not respond to the news agency’s requests. As of the latest reporting, no confirmed date for the resumption of regular 777F production has been announced.
