Reverse engineering

Using digital processes accelerates design and increases manufacturing quality.

During the development of the 777, Boeing used new approaches to designing and building, creating the first airplane that was 100% digitally designed and preassembled on computer. The 777 program established design/build teams to develop each element of the airplane's airframe or system. Under this approach, all of the different specialists involved in airplane development-designers, manufacturing and tooling engineers, finance, suppliers, customers and others-worked jointly to create the new airplane. Based at the same location, team members worked concurrently, sharing their knowledge rather than applying their skills sequentially.

Communication among the program's 238 design/build teams was enhanced by sophisticated computers linked by the largest mainframe installation of its kind in the world. Using 3D digital software, designers could see parts as solid images and then simulate the assembly of those parts on the screen, easily correcting misalignments and other fit or interference problems.