FedEx has resumed commercial operations of its MD-11 freighter fleet after the Federal Aviation Administration approved Boeing’s corrective measures designed to resolve structural issues that led to the grounding of the aircraft type late last year.
The development marks the first commercial MD-11 flights operated by FedEx since early November, following the dramatic UPS cargo aircraft incident in Louisville, Kentucky, which prompted regulators to suspend operations pending further investigation.
According to the FAA, Boeing’s proposed return-to-service protocol underwent an extensive review before receiving approval.
“After a thorough review, the FAA approved Boeing’s protocol for safely returning MD-11 aircraft to service,” the agency confirmed in a statement shared with FreightWaves.
FedEx conducted a test flight at Memphis International Airport on Saturday evening before reintroducing the aircraft into commercial service. Flight tracking data from Flightradar24 showed that one MD-11 operated a route from Memphis to Los Angeles International Airport on Sunday, while another aircraft completed a flight between Memphis and Miami.
The company had previously announced plans to progressively reactivate its fleet of 29 McDonnell Douglas MD-11 freighters after jointly developing a redesigned component with Boeing. The new part addresses a defect responsible for fatigue cracking identified within the aircraft structure.
During an internal briefing last week, FedEx informed employees that the remaining aircraft would gradually return to operation after undergoing maintenance procedures, including replacement of the affected component and pilot refresher training.
The issue emerged after UPS Flight 2976 crashed shortly after takeoff from Louisville when its left engine detached from the wing. A preliminary investigation conducted by the National Transportation Safety Board found fatigue cracks within the pylon connecting the engine to the wing structure. Investigators traced the problem to a bearing located inside one of the pylon attachment fittings.
FedEx stated that pylons from grounded aircraft stationed worldwide would be removed and transported to its maintenance centers in Memphis and Indianapolis, where the bearing replacement program would be carried out.
Despite the aircraft’s age, FedEx confirmed it intends to continue operating its MD-11 fleet through 2032 to support rising global cargo demand. UPS, however, has decided to retire its own MD-11 fleet from service.
