Leaders in Aviation Product Liability Law

Common Types of Aviation Defects

Design Defects

A design defect occurs when an aircraft or component is inherently unsafe due to flawed engineering, even if it is manufactured exactly as intended. In aviation, this might involve inadequate structural support, faulty control system logic, or a design that cannot perform safely under normal flight conditions.

Examples include rudder systems prone to jamming, fuel tank placement that increases fire risk, or automation systems that override pilot input without safeguards.

Manufacturing Defects

These arise when an aircraft or part deviates from its intended design during the production process. A manufacturing defect may result from poor quality control, substandard materials, or errors in assembly.

Common examples include missing bolts, cracked turbine blades, or improperly installed avionics that cause in-flight system failures.

Warning Defects

Manufacturers must provide clear warnings and instructions regarding safe operation, maintenance, and potential risks. A failure to warn claim may involve omitted advisories about component fatigue limits, improper inspection intervals, or insufficient guidance on emergency procedures.

In aviation, even small omissions in a maintenance manual or safety bulletin can have catastrophic consequences. 

How Defective Aviation Products Cause Accidents

Whether it’s a failed engine part, malfunctioning sensor, or improperly installed system, a single defective component can trigger mechanical failure, destabilize flight controls, or result in emergency landings and passenger injuries. These defects often stem from rushed production, poor oversight, or missed issues during certification.

When a defect is identified, liability may shift away from the pilot or operator and toward the manufacturer, supplier, or maintenance provider involved. However, the General Aviation Revitalization Act (GARA) can limit the ability to sue manufacturers if the part or aircraft was delivered more than 18 years before the crash.

How Our Attorneys Investigate Aviation Product Liability Cases?

At Podhurst Orseck, we routinely litigate aviation product liability claims and have extensive experience challenging premature GARA defenses. Our team investigates flight data, FDR/CVR records, maintenance logs, FAA directives, and manufacturer quality reports to build strong cases and hold the right parties accountable—even when the part’s origin is unclear or GARA is cited as a defense.

We work with top aerospace engineers and regulatory experts to navigate the technical and procedural challenges these cases often present.

Defective Aviation Products & Related Accidents

Aviation accidents involving defective products often stem from seemingly minor mechanical or electrical issues—yet their consequences can be catastrophic. At Podhurst Orseck, we’ve handled claims involving a wide variety of aircraft defects, including:

• Defective Autopilot Systems: Causing loss of altitude control, improper turns, or inability to disengage in emergencies.
• Faulty Rudder or Elevation Controls: Resulting in in-flight instability or uncontrollable pitch and yaw, sometimes ending in fatal crashes.
• Engine Component Failures: Including turbine blade fractures, fuel injector defects, and oil pump malfunctions leading to mid-air engine failure.
• Avionics Malfunctions: GPS, altimeter, or attitude indicator failures causing spatial disorientation or CFIT (Controlled Flight Into Terrain).
• Improper Electrical Wiring or Short Circuits: Contributing to in-cabin fires or avionics shutdowns.

Each scenario represents not just a design or manufacturing failure, but a missed opportunity to prevent loss of life. Our firm has successfully litigated general and commercial aviation claims, often where others have turned victims away due to technical complexity.