See inside Boeing's first-ever 777X aircraft testing tech like the jet's revolutionary folding wingtips

Stephen Jones,Taylor RainsAug 13, 2022, 18:44 IST

Boeing 777X Flight Test 1 aircraft at the Farnborough Air Show 2022.Stephen Jones/Insider

Boeing announced its next-generation 777X passenger jet at the Dubai Airshow in 2013.
The plane is a stretched version of Boeing's successful 777-200/300, but with reduced emissions and operating costs.

The Boing 777X is the planemaker's newest passenger aircraft, having first flown in January 2020.

Boeing 777X.Boeing

The jet is the third generation of Boeing's successful 777 family, stretching longer than the 777-200 and 777-300 models.

El Al Israel Airlines Boeing 777-200ER.Fabrizio Gandolfo/SOPA Images/LightRocket/Getty Images

Boeing will initially build the 777X as the 777-9, which will be the world's largest twin-engine jet, with plans to build the smaller 777-8 variant in the future.

Boeing 777-8 and 777-9 passenger planes.Boeing

The company also has plans for a freighter version — the 777-8F — as cargo demand continues to skyrocket. Qatar Airways will be the launch customer, with the first delivery expected for 2027.

Qatar Airways 777-8F rendering.Qatar Airways

The company also has plans for a freighter version — the 777-8F — as cargo demand continues to skyrocket. Qatar Airways will be the launch customer, with the first delivery expected for 2027.

According to Boeing, the 777-9 is currently the largest passenger aircraft in production.

Flight Test 1 being built.Boeing

The Airbus A380 previously held the title, but the program ended in 2019 due to low demand for the jet. Emirates, which operates 118 A380s, was the only carrier to make a significant investment in the double-decker plane.

An Emirates Airbus A380.Arnold Aaron/Shutterstock.com

The Airbus A380 previously held the title, but the program ended in 2019 due to low demand for the jet. Emirates, which operates 118 A380s, was the only carrier to make a significant investment in the double-decker plane.

The 777-9 is also the longest commercial airliner ever built at 251 feet and nine inches, beating out the Boeing 747-8, which is just two and a half feet shorter at 250 ft and two inches. The 777-8 will be shorter at 229 feet.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

The 777-9 is also the longest commercial airliner ever built at 251 feet and nine inches, beating out the Boeing 747-8, which is just two and a half feet shorter at 250 ft and two inches. The 777-8 will be shorter at 229 feet.

The flagship 777X takes the success of the 777's large airframe and long-range capabilities and builds upon that with improved efficiency and lower operating costs.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Insider went onboard the manufacturer's first-ever 777X test plane, known as Flight Test 1, at the Farnborough International Air Show in England to learn more about the program — take a look.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones/Insider

Insider went onboard the manufacturer's first-ever 777X test plane, known as Flight Test 1, at the Farnborough International Air Show in England to learn more about the program — take a look.

The plane is powered by two large GE9X engines made by General Electric. A Boeing 737's fuselage could fit inside one of the 777X's engines.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

The engines power the plane's 13,500-kilometer range (8,388 miles) and offer 10% lower fuel costs compared to the 777-300ER, according to Boeing.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Inside the jet is a slew of testing equipment and tools, with one of the most important being the large black water tanks located at the front and back of the plane.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Engineering captain Edwin Navarro told Insider the tanks help control the 777X's center of gravity (CG), which is necessary for analyzing the stability of the aircraft.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

He explained that engineers shift water between the tanks via pipes to change the plane's CG. Because some tests need a specific CG, the barrels are important for testing very niche conditions.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones / Insider

He explained that engineers shift water between the tanks via pipes to change the plane's CG. Because some tests need a specific CG, the barrels are important for testing very niche conditions.

Behind the tanks are several rows of seats arranged as they would be in an economy class. These are for ferrying Boeing staff between test flights.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones/ Insider

The seats give a preview of what a completed 777X interior could look like. The plane is built for ten-abreast seats in economy, which would accommodate up to 426 passengers in a two-class configuration — 30 more than the 777-300ER.

Air New Zealand 777-300ER economy cabin with 10-abreast seats.Phillip Capper

The seats give a preview of what a completed 777X interior could look like. The plane is built for ten-abreast seats in economy, which would accommodate up to 426 passengers in a two-class configuration — 30 more than the 777-300ER.

The dense layout is common on the current 777, but the 777X will offer more room so passengers can travel more comfortably.

As the world's two biggest plane makers, Boeing and Airbus are great rivals.Stephen Jones/ Insider

The configuration competes with the rival Airbus A350. Historically, mainline carriers have only configured the plane with nine seats abreast, minus a few budget airlines like French Bee that have squeezed in ten.

Ten seats abreast on French bee's A350.Taylor Rains/Insider

The configuration competes with the rival Airbus A350. Historically, mainline carriers have only configured the plane with nine seats abreast, minus a few budget airlines like French Bee that have squeezed in ten.

However, Airbus is working on a denser cabin configuration that would allow for ten-abreast in economy "without compromising seat width," company CCO Christian Scherer told FlightGlobal.

Nine seats abreast on Italian carrier ITA's A350.Taylor Rains/Insider

However, Airbus is working on a denser cabin configuration that would allow for ten-abreast in economy "without compromising seat width," company CCO Christian Scherer told FlightGlobal.

Boeing has also innovated the windows on its 777X to compete with the A350. Flight Test 1 had an example of an A350 window in its cabin to visually compare.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones / Insider

According to Boeing, the 777X's windows are placed higher on the fuselage and are 29% bigger to make the plane feel more spacious and give every passenger a better view.

Boeing 777X interior rendering.Boeing

According to Boeing, the 777X's windows are placed higher on the fuselage and are 29% bigger to make the plane feel more spacious and give every passenger a better view.

In the middle and the back of the plane is where engineers sit during test flights.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones / Insider

The area is affectionately called 'The Pit,' test director Wesley Herbert told Insider. Engineers bring their own laptops to hook up to the stations.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

The seats are padded and come with a drink holder and a five-point harness.

Stephen Jones / Insider

Each bank, which includes a TV screen and other tools, monitors a different part of the plane's flight systems, including instrumentation, engines, and weight.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones / Insider

A lot of the instrumentation, like orange wiring throughout the cabin, is purely used for testing and is not in production aircraft. It sends information to the engineers so they can analyze data in real-time to ensure the plane is performing.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

A lot of the instrumentation, like orange wiring throughout the cabin, is purely used for testing and is not in production aircraft. It sends information to the engineers so they can analyze data in real-time to ensure the plane is performing.

Herbert told Insider that the average test flight lasts between three to four hours, although they can last as long as eight.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Stephen Jones / Insider

According to Boeing experimental test pilot James Murrell, the aircraft is one of four 777X planes in the company's fleet, all of which are based at Boeing Field in Washington state.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

According to Boeing experimental test pilot James Murrell, the aircraft is one of four 777X planes in the company's fleet, all of which are based at Boeing Field in Washington state.

Murrell told Insider that Flight Test 1 has flown about 1,100 hours across more than 400 test flights. As a fleet, the planes have flown a collective 2,500 hours across about 800 test flights.

Boeing 777X flying display at the Farnborough International Air Show 2022.Taylor Rains/Insider

Murrell told Insider that Flight Test 1 has flown about 1,100 hours across more than 400 test flights. As a fleet, the planes have flown a collective 2,500 hours across about 800 test flights.

The company has also rolled out 20 production aircraft for customers.

A Boeing 777X aircraft being built by Boeing.Stephen Brashear/Getty

Murrell explained Flight Test 1 is mainly testing the jet's characteristics, like folding wing tips, which are a brand new technology.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

At 235 feet and five inches, the 777X has a 23-foot longer wing span than former 777 models when the wingtips are folded down.

Boeing 777X wingspan.Boeing

Boeing increased the 777X's wingspan to generate more lift, which reduces fuel burn by about 10% and makes the plane more efficient than its predecessors.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

However, the longer wingspan would not fit at most airport gates. To eliminate the need for new infrastructure to accommodate the wider jet, Boeing needed a mechanism that folds the wingtips up when parked.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

However, the longer wingspan would not fit at most airport gates. To eliminate the need for new infrastructure to accommodate the wider jet, Boeing needed a mechanism that folds the wingtips up when parked.

When retracted, the 777X's wingspan is the same length as the older 777s, meaning they can fit into airport gates that are already built for current 777 variants.

Air New Zealand Boeing 777 at the gate at LAX.Thiago B Trevisan/Shutterstock

According to Murrell, the wingtips are safe due to the redundancies built into the plane.

Boeing 777X.Boeing

"We have a whole slew of alerts that make sure the wingtips are extended prior to takeoff," he said. "It's part of our before takeoff checklist, which is electronic."

Inside the Boeing 777X cockpit.Thomas Pallini/Insider

Murrell explained that a switch in the cockpit will signal to the checklist that the wingtips are fully extended. "I can't takeoff without that, he said. "The auto-throttles won't work, and alarms will sound in the cockpit."

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Murrell explained that a switch in the cockpit will signal to the checklist that the wingtips are fully extended. "I can't takeoff without that, he said. "The auto-throttles won't work, and alarms will sound in the cockpit."

He further explained that the entire system is mechanically locked once airborne, so nothing can be changed during flight. But, as the plane lands and slows to about 50 knots, the wingtips automatically fold.

The Boeing 777X at Dubai Airshow 2021.Thomas Pallini/Insider

He further explained that the entire system is mechanically locked once airborne, so nothing can be changed during flight. But, as the plane lands and slows to about 50 knots, the wingtips automatically fold.

In the case of a go-around, the wingtips will still be deployed because the plane has to be on the ground and at a certain speed to fold.

Boeing 777X.AP Photo/Ted S. Warren

Murrell also explained that the wingtips are "easy to use and are just a switch in the cockpit," so the system would be a simple transition for crews switching from flying former 777 models to the 777X.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Murrell also explained that the wingtips are "easy to use and are just a switch in the cockpit," so the system would be a simple transition for crews switching from flying former 777 models to the 777X.

However, he said that during test flights, the pilots will note how the crew interacts with the system and if any human factors-related things could be improved.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

As far as the flight deck as a whole, Murrell said the 777X is similar to the 787. The cockpit has all touchscreen displays, which he said are intuitive and effective.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

While Flight Test 1 has its own schedule and specific tests, other aircraft in the fleet have their own purpose. For example, one plane has a nearly complete interior, so that jet is meant for more cabin-related tests.

Boeing 777X interior mockup.Boeing

While Flight Test 1 has its own schedule and specific tests, other aircraft in the fleet have their own purpose. For example, one plane has a nearly complete interior, so that jet is meant for more cabin-related tests.

Meanwhile, Murrell told Insider that Flight Test 2 just completed a campaign that tested how the plane performed with artificial ice sheets on the wing's leading edge. "If you have that amount of ice, you want to make sure the plane still flies well, and it does," he said.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

Meanwhile, Murrell told Insider that Flight Test 2 just completed a campaign that tested how the plane performed with artificial ice sheets on the wing's leading edge. "If you have that amount of ice, you want to make sure the plane still flies well, and it does," he said.

While the 777X is still in the testing phase, Boeing hopes the plane will have its first delivery by 2025.

Boeing 777X Flight Test 1 aircraft at the Farnborough International Air Show 2022.Taylor Rains/Insider

However, the goal is already well-past Boeing's original plan, which expected the first jet to be delivered in 2020. Moreover, the planemaker has also stopped production of the jet until at least the end of 2023.

Boeing 777X parked at Paine Field in Everett, Washington.AP Photo/Elaine Thompson

However, the goal is already well-past Boeing's original plan, which expected the first jet to be delivered in 2020. Moreover, the planemaker has also stopped production of the jet until at least the end of 2023.

The move comes after the Federal Aviation Administration told Boeing that its current certification plan for the 737 MAX 10 and 777X were "outdated and no longer reflect the program activities."

Boeing 737 MAX 10.Taylor Rains/Insider

The move comes after the Federal Aviation Administration told Boeing that its current certification plan for the 737 MAX 10 and 777X were "outdated and no longer reflect the program activities."

Boeing said the delay would cost a whopping $1.5 billion but is necessary to stop "producing airplanes which we then may have to rebuild and rework," the Seattle Times reported.

Boeing 777X in Everett, Washington.AP Photo/Ted S. Warren

Boeing said the delay would cost a whopping $1.5 billion but is necessary to stop "producing airplanes which we then may have to rebuild and rework," the Seattle Times reported.

While Boeing is temporarily halting production, with London-based analyst firm Agency Partners calling the announcement a "dreadful set of results," Emirates CEO Tim Clark told Simple Flying that he is still committed to the 777X.

Emirates Boeing 777X rendering.Boeing

While Boeing is temporarily halting production, with London-based analyst firm Agency Partners calling the announcement a "dreadful set of results," Emirates CEO Tim Clark told Simple Flying that he is still committed to the 777X.

"As far as the 787s are concerned, we're having a good hard look to see whether they fit into the program or not," he said. "It's far more important to us that they (Boeing) concentrate on getting their 777X out the door."

Emirates Boeing 777-9, Boeing 777-8, and Boeing 787 rendering.Boeing

"As far as the 787s are concerned, we're having a good hard look to see whether they fit into the program or not," he said. "It's far more important to us that they (Boeing) concentrate on getting their 777X out the door."

Emirates currently has 115 Boeing 777X planes on order — down from 150 it originally ordered in 2013.

Emirates Boeing 777X rendering.Boeing

In addition to Emirates, Boeing has seven other 777X customers, like Qatar Airways...

Qatar Boeing 777X rendering.Boeing

...British Airways...

British Airways Boeing 777X rendering.Boeing

...and Hong Kong-based Cathay Pacific Airways. So far, the planemaker does not have any orders from US airlines.

Cathay Pacific 777X rendering.Boeing

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See inside Boeing's first-ever 777X aircraft testing tech like the jet's revolutionary folding wingtips

The Boing 777X is the planemaker's newest passenger aircraft, having first flown in January 2020.

The jet is the third generation of Boeing's successful 777 family, stretching longer than the 777-200 and 777-300 models.

Boeing will initially build the 777X as the 777-9, which will be the world's largest twin-engine jet, with plans to build the smaller 777-8 variant in the future.

The company also has plans for a freighter version — the 777-8F — as cargo demand continues to skyrocket. Qatar Airways will be the launch customer, with the first delivery expected for 2027.

According to Boeing, the 777-9 is currently the largest passenger aircraft in production.

The Airbus A380 previously held the title, but the program ended in 2019 due to low demand for the jet. Emirates, which operates 118 A380s, was the only carrier to make a significant investment in the double-decker plane.

The 777-9 is also the longest commercial airliner ever built at 251 feet and nine inches, beating out the Boeing 747-8, which is just two and a half feet shorter at 250 ft and two inches. The 777-8 will be shorter at 229 feet.

The flagship 777X takes the success of the 777's large airframe and long-range capabilities and builds upon that with improved efficiency and lower operating costs.

Insider went onboard the manufacturer's first-ever 777X test plane, known as Flight Test 1, at the Farnborough International Air Show in England to learn more about the program — take a look.

The plane is powered by two large GE9X engines made by General Electric. A Boeing 737's fuselage could fit inside one of the 777X's engines.

The engines power the plane's 13,500-kilometer range (8,388 miles) and offer 10% lower fuel costs compared to the 777-300ER, according to Boeing.

Inside the jet is a slew of testing equipment and tools, with one of the most important being the large black water tanks located at the front and back of the plane.

Engineering captain Edwin Navarro told Insider the tanks help control the 777X's center of gravity (CG), which is necessary for analyzing the stability of the aircraft.

He explained that engineers shift water between the tanks via pipes to change the plane's CG. Because some tests need a specific CG, the barrels are important for testing very niche conditions.

Behind the tanks are several rows of seats arranged as they would be in an economy class. These are for ferrying Boeing staff between test flights.

The seats give a preview of what a completed 777X interior could look like. The plane is built for ten-abreast seats in economy, which would accommodate up to 426 passengers in a two-class configuration — 30 more than the 777-300ER.

The dense layout is common on the current 777, but the 777X will offer more room so passengers can travel more comfortably.

The configuration competes with the rival Airbus A350. Historically, mainline carriers have only configured the plane with nine seats abreast, minus a few budget airlines like French Bee that have squeezed in ten.

However, Airbus is working on a denser cabin configuration that would allow for ten-abreast in economy "without compromising seat width," company CCO Christian Scherer told FlightGlobal.

Boeing has also innovated the windows on its 777X to compete with the A350. Flight Test 1 had an example of an A350 window in its cabin to visually compare.

According to Boeing, the 777X's windows are placed higher on the fuselage and are 29% bigger to make the plane feel more spacious and give every passenger a better view.

In the middle and the back of the plane is where engineers sit during test flights.

The area is affectionately called 'The Pit,' test director Wesley Herbert told Insider. Engineers bring their own laptops to hook up to the stations.

The seats are padded and come with a drink holder and a five-point harness.

Each bank, which includes a TV screen and other tools, monitors a different part of the plane's flight systems, including instrumentation, engines, and weight.

A lot of the instrumentation, like orange wiring throughout the cabin, is purely used for testing and is not in production aircraft. It sends information to the engineers so they can analyze data in real-time to ensure the plane is performing.

Herbert told Insider that the average test flight lasts between three to four hours, although they can last as long as eight.

According to Boeing experimental test pilot James Murrell, the aircraft is one of four 777X planes in the company's fleet, all of which are based at Boeing Field in Washington state.

Murrell told Insider that Flight Test 1 has flown about 1,100 hours across more than 400 test flights. As a fleet, the planes have flown a collective 2,500 hours across about 800 test flights.

The company has also rolled out 20 production aircraft for customers.

Murrell explained Flight Test 1 is mainly testing the jet's characteristics, like folding wing tips, which are a brand new technology.

At 235 feet and five inches, the 777X has a 23-foot longer wing span than former 777 models when the wingtips are folded down.

Boeing increased the 777X's wingspan to generate more lift, which reduces fuel burn by about 10% and makes the plane more efficient than its predecessors.

However, the longer wingspan would not fit at most airport gates. To eliminate the need for new infrastructure to accommodate the wider jet, Boeing needed a mechanism that folds the wingtips up when parked.

When retracted, the 777X's wingspan is the same length as the older 777s, meaning they can fit into airport gates that are already built for current 777 variants.

According to Murrell, the wingtips are safe due to the redundancies built into the plane.

"We have a whole slew of alerts that make sure the wingtips are extended prior to takeoff," he said. "It's part of our before takeoff checklist, which is electronic."

Murrell explained that a switch in the cockpit will signal to the checklist that the wingtips are fully extended. "I can't takeoff without that, he said. "The auto-throttles won't work, and alarms will sound in the cockpit."

He further explained that the entire system is mechanically locked once airborne, so nothing can be changed during flight. But, as the plane lands and slows to about 50 knots, the wingtips automatically fold.

In the case of a go-around, the wingtips will still be deployed because the plane has to be on the ground and at a certain speed to fold.

Murrell also explained that the wingtips are "easy to use and are just a switch in the cockpit," so the system would be a simple transition for crews switching from flying former 777 models to the 777X.

However, he said that during test flights, the pilots will note how the crew interacts with the system and if any human factors-related things could be improved.

As far as the flight deck as a whole, Murrell said the 777X is similar to the 787. The cockpit has all touchscreen displays, which he said are intuitive and effective.

While Flight Test 1 has its own schedule and specific tests, other aircraft in the fleet have their own purpose. For example, one plane has a nearly complete interior, so that jet is meant for more cabin-related tests.

Meanwhile, Murrell told Insider that Flight Test 2 just completed a campaign that tested how the plane performed with artificial ice sheets on the wing's leading edge. "If you have that amount of ice, you want to make sure the plane still flies well, and it does," he said.

While the 777X is still in the testing phase, Boeing hopes the plane will have its first delivery by 2025.

However, the goal is already well-past Boeing's original plan, which expected the first jet to be delivered in 2020. Moreover, the planemaker has also stopped production of the jet until at least the end of 2023.

The move comes after the Federal Aviation Administration told Boeing that its current certification plan for the 737 MAX 10 and 777X were "outdated and no longer reflect the program activities."

Boeing said the delay would cost a whopping $1.5 billion but is necessary to stop "producing airplanes which we then may have to rebuild and rework," the Seattle Times reported.

While Boeing is temporarily halting production, with London-based analyst firm Agency Partners calling the announcement a "dreadful set of results," Emirates CEO Tim Clark told Simple Flying that he is still committed to the 777X.

"As far as the 787s are concerned, we're having a good hard look to see whether they fit into the program or not," he said. "It's far more important to us that they (Boeing) concentrate on getting their 777X out the door."

Emirates currently has 115 Boeing 777X planes on order — down from 150 it originally ordered in 2013.

In addition to Emirates, Boeing has seven other 777X customers, like Qatar Airways...

...British Airways...

...and Hong Kong-based Cathay Pacific Airways. So far, the planemaker does not have any orders from US airlines.