First Hole Drilled Marks Official Start of Assembly for World’s Largest Twin-Engine Cargo Aircraft

A new chapter in cargo aviation officially took flight this week as Boeing commenced production of the 777-8 Freighter, the newest member of the 777X family. In a symbolic and technically significant moment, Boeing teammate Casey McDowell drilled the first hole into the composite wing spar, marking the formal start of major assembly at the company’s Composite Spar Shop in Everett, Washington.

By Jarryd Sinovich

The occasion was met with cheers from a crowd of roughly 100 team members who gathered to witness the milestone. “You don’t forget these moments,” said McDowell. “Having our team together as we got underway on this airplane was special.”

Building the Future of Air Cargo

Launched in 2022, the 777-8 Freighter is poised to become the world’s largest and most efficient twin-engine freighter, according to Boeing. With 59 aircraft already on order, the freighter is scheduled for first delivery in 2028, promising to set new standards for performance, fuel efficiency, and environmental responsibility in long-haul cargo transport.

The new freighter joins its siblings—the 777-9 and 777-8 passenger models—as part of the advanced 777X widebody family, combining the proven reliability of the 777 platform with cutting-edge technologies borrowed from the 787 Dreamliner.

A Legacy of Craftsmanship

For Robin Thorning, a longtime automation manager with nearly four decades at Boeing, this moment was deeply personal. “I helped build the very first 777 – WA001 – early in my career, and it’s exciting to get to start our newest member of the 777X family,” he said.

Thorning is part of a proud Boeing family legacy, with his father, son, and daughter contributing nearly a century of combined service to the aerospace giant. “To touch these incredible airplanes and help bring them to life is a privilege and really a once-in-a-lifetime opportunity,” he added. “We take our work seriously as we continue to drive to build safe and more-efficient airplanes.”

Cutting-Edge Manufacturing

The 777-8 Freighter’s wings will be constructed using components fabricated at Boeing’s nearby Composite Wing Center (CWC). Each wing requires a pair of massive 108-foot-long spars, front and rear, built from 392 miles of carbon fiber tape—roughly equivalent to the driving distance from Everett to Montana. Once completed, each spar pair weighs in at a combined 2,500 pounds.

Alongside the spars, the CWC also produces other essential wing elements, including skin panels and stringers. These components will be transported to the main assembly plant for integration into the aircraft’s full wing structure.

What’s Next

With spar fabrication underway, the next major milestone will be the full wing assembly using CWC parts and additional components. From there, the structure will move down the production line as Boeing prepares the first test aircraft in the lead-up to flight testing and certification.

“You are leading the way as we introduce our newest freighter into our production system,” said Jason Clark, Boeing vice president and general manager for the 777/777X program. “Thank you for building our future.”

About the 777-8 Freighter
Part of Boeing’s next-generation widebody lineup, the 777-8 Freighter combines the advanced composite wing design and aerodynamics of the 777X family with the structural payload capabilities demanded by cargo operators. With long-range capability, improved fuel burn, and high cargo volume, the aircraft is positioned to redefine air freight for decades to come.