Airbus A380 wing slats are falling apart: Emirates and Singapore Airlines affected
July 25, 2025
Airbus is set to mandate new safety inspections across its iconic A380 fleet following a series of structural defects found in the aircraft’s leading-edge slats.
This follows an in-depth investigation by the French air accident authority, the Bureau d’Enquêtes et d’Analyses (BEA), into an incident involving Emirates flight EK77 during its approach to Nice Côte d’Azur Airport in August 2023.
As the world’s largest passenger aircraft celebrates its 20th anniversary this year, the A380’s longevity and operational safety remain a priority for Airbus, despite ending production in 2021.
Emirates Airbus A380 lands with partially destroyed slats
On 18 August 2023, Emirates flight EK77, an A380 registered A6-EOM, was on approach to Nice Airport when pilots selected configuration 1 – deploying the leading-edge slats designed to optimise lift for landing.
At approximately 3,500 feet and travelling at 212 knots, the crew noticed a muffled noise followed by slight vibrations. Despite these unusual signs, the aircraft continued its approach and landed safely with no system warnings or alerts.
Upon inspection on the ground, maintenance teams discovered severe damage to slat number 2 on the right-hand wing. The damage extended across about two-thirds of the trailing edge, with the upper and lower skins torn and the honeycomb core partially missing.
The BEA promptly classified the event as an accident due to the potential risks such damage posed to flight performance and safety. Initial concerns included a possible mid-air collision with a drone or bird strike.
However, detailed examinations of the damaged slat and forensic analysis, including ultraviolet light inspections, found no evidence of external impact.
Bonding defects identified on the Airbus A380
The leading-edge slats on the A380, and all Airbus aircraft since the A310, are composed of two primary parts: a metal box containing the leading edge and attachment mechanisms, and a trailing edge made of a metal sandwich composite structure riveted to the box.
The BEA’s investigation confirmed that while the trailing edge sustained significant damage, the main slat structure remained intact, minimising the risk of complete dislocation.
Critically, the BEA identified bonding defects within the composite trailing edge. These defects involved ruptures between the honeycomb core and the upper and lower skin layers.
Airbus production partner, Belgian manufacturer Sonaca, reported no deviations in manufacturing processes or production records, suggesting the defects arose post-production.
Three Singapore Airlines Airbus A380s have similar problems
In the seven months following the Emirates event, three similar occurrences involving Singapore Airlines A380s were reported. These incidents involved damage to slats during extension phases, again without evidence of external impact.
Although the authorities did not open investigations into these subsequent events, Airbus took note and initiated thorough examinations.
In response, Airbus is preparing to issue two service bulletins in January 2026, mandating repetitive inspections of the leading-edge slats during scheduled A and C maintenance checks.
These inspections will specifically look for cracks, delamination, and signs of bonding failure to ensure early detection and prevention.
Airbus reassures on A380 safety
Simulations conducted by Airbus indicate that the observed damage does not significantly affect lift or overall flight safety margins. Consequently, the BEA has reclassified the original occurrence from an accident to an incident.
Nonetheless, the findings underline the importance of vigilance and proactive maintenance to maintain the A380’s airworthiness.
The European Union Aviation Safety Agency (EASA) continues to supervise Airbus’ investigations and corrective actions, reinforcing the regulatory framework that ensures aviation safety standards are met globally.
This year marks the 20th anniversary of the A380’s maiden flight on 27 April 2005. The aircraft’s new technologies and designs helped Airbus to become a leading player in commercial aviation.
While the recent findings have prompted new safety protocols, they also exemplify the ongoing dedication of Airbus and the global aviation community to ensuring the A380 remains one of the safest and most reliable aircraft in operation.
