Broken engine components caused a Ryanair plane’s window to shatter just after takeoff in Greece last month, resulting in a passenger’s head being pulled partially through the opening before fellow passengers managed to retrieve him, according to U.S. investigators on Thursday.
A fan blade in the right engine of the Boeing 737-800 broke off, leading to fragments damaging the window and the fuselage in multiple areas, as outlined in a preliminary report by the U.S. National Transportation Safety Board (NTSB).
Following international aviation regulations, Greece transferred the inquiry to the U.S. agency. The incident occurred on July 10 after the aircraft left Thessaloniki in northern Greece. Investigators discovered bird remnants inside the engine, hinting that the plane likely collided with birds during takeoff, although the exact cause of the fan blade detachment remains undetermined.
The 61-year-old passenger involved sustained neck and shoulder injuries and friction burns as a result of his head being drawn towards the window.
Flight attendants reported hearing loud, persistent vibrations and observed smoke or mist filling the cabin before emergency oxygen masks deployed from the ceiling. Passengers in Row 11 noticed a man partially stuck in the damaged window and managed to pull him back into the cabin.
The injured passenger received medical attention in Row 12, with other passengers utilizing a metal box obtained from the flight attendants to cover the opening until the plane landed safely.
Videos captured inside the plane showed passengers wearing oxygen masks after the cabin depressurized, with one clip revealing the blown-out window near a man wearing an oxygen mask. Subsequent footage depicted first responders attending to the situation after the aircraft landed.
While maintenance records indicated that the failed fan blades underwent ultrasonic inspections in May 2026 and November 2025 without finding any damage, the NTSB noted four previous suspected bird strikes reported by flight crews on the same engine within the past year, with bird remnants discovered after two incidents.
Ryanair announced its decision to withhold further comments until the conclusion of the NTSB investigation. Boeing and CFM International, the engine manufacturer, affirmed their cooperation in the investigation.
In response to prior fan blade failures, the FAA issued three directives in 2025 mandating airlines to reinforce certain sections of engine coverings on Boeing 737s to prevent detached fan blade pieces from hitting the aircraft. The deadline for implementing these modifications was set for July 2028, with the NTSB report indicating that the required changes had not yet been made to the Ryanair plane.
Experts suggested that the recent incident might prompt a reassessment of the deadline by the FAA and NTSB. The FAA refrained from commenting on the ongoing investigation, emphasizing its close collaboration with the NTSB and readiness to take necessary safety actions based on evidence.
The 737-800 involved in the episode, capable of accommodating up to 189 passengers, was delivered new to Ryanair in 2008. Flight data revealed the aircraft ascended above 4,570 meters around six minutes post-takeoff before rapidly descending to about 1,830 meters to burn fuel for half an hour and then return to Thessaloniki approximately an hour after departure.
Operated by Malta Air, a Ryanair subsidiary, Europe’s largest budget carrier, the flight concluded with a normal landing, allowing passengers to disembark and return to the terminal. Medical assistance was provided to one passenger upon arrival, as stated by the airline in a prior announcement.
