UPS MD-11 Crash: NTSB Releases Preliminary Report & Dramatic Images

Image credit: Unsplash

On 4 November 2025, a UPS McDonnell Douglas MD-11 freighter (Flight 2976) crashed shortly after takeoff from Louisville Muhammad Ali International Airport (SDF), Kentucky, resulting in a tragic loss of life and a major safety investigation. On 20 November 2025, the National Transportation Safety Board (NTSB) published a preliminary report — along with jaw-dropping frame-by-frame photos — revealing key findings, including fatigue cracks in the engine pylon, overstress failure, and the separation of the left engine during takeoff.

What the NTSB Found

Image credit : NTSB

Engine Separation & Structural Failure

According to the preliminary report, the MD-11 reached only about 30 feet above the ground before disaster struck. Witnesses in the control tower reported the aircraft did not climb normally, and it rolled slightly to the left.  The NTSB confirmed that the left engine and its pylon detached from the plane during takeoff, a catastrophic failure that immediately preceded a fire on the left wing.

Photos released by the NTSB show the engine flying up and over the wing, engulfed in flames — a terrifying sequence captured in six images.

Fatigue Cracks & Overstress Failures

Investigators discovered fatigue cracks in a critical structural component — the left pylon’s aft mount lug (the part that attaches the pylon and thus the engine to the wing).  These cracks, compounded by evidence of overstress, suggest that the structural supports had been under repeated strain over multiple flight cycles.

The NTSB also reported fractures in the spherical bearing that helps secure the pylon, which likely contributed to the separation.

Maintenance & Inspection Issues

The MD-11 involved had almost 93,000 flight hours and more than 21,000 cycles, according to the report.  NTSB documents revealed that while the aircraft had undergone routine inspections, a detailed “special” inspection for the pylon lugs was not yet due at the time of the crash.

Notably, the pylon had last been inspected in October 2021, more than four years before the accident — and far short of the cycle count at which a special inspection would normally be mandated.

Flight Data & Voice Recorders Recovered

Both the cockpit voice recorder (CVR) and flight data recorder (FDR) were successfully recovered. According to the NTSB, about two hours of CVR audio and 63 hours of flight data were available for analysis, including the accident flight.  This data will be crucial for fully understanding the sequence of events and what the flight crew experienced in those final moments.

Historical Parallel

The NTSB preliminary report draws a comparison to a tragic accident from 1979: American Airlines Flight 191, a DC-10 that lost its left engine during takeoff due to pylon failure.  The similarity in failure mode has raised concerns and renewed scrutiny about aging three-engine cargo jets.

Operational & Industry Impact

Fleet Grounding

In the immediate aftermath of the crash, both UPS and FedEx grounded their respective MD-11 fleets as a precaution.  The FAA followed with emergency directives, grounding the MD-11 (and related DC-10 models) until inspections and corrective actions are completed.

Safety & Regulatory Ramifications

This crash raises serious questions about how aging aircraft are maintained, especially for components that may suffer high stress. The fact that the critical pylon mount parts had fatigue cracks but were not yet due for a detailed inspection has led to calls for regulatory review of inspection intervals and standards for older cargo aircraft.

It also underscores the role of oversight agencies like the NTSB and FAA in ensuring structural integrity across fleets — particularly for multi-decade-old aircraft.

Human Toll & Community Impact

Fourteen lives were lost in this tragedy: all three crew members aboard the MD-11 and 11 people on the ground in the industrial area near the airport.  The crash site stretched over 3,000 feet, striking a UPS warehouse, a petroleum recycling facility, and other buildings.

Louisville’s mayor confirmed there were no missing; the count of 14 deaths matched the number initially reported, including one person who died later in the hospital.  It was a stark reminder of the risks to airport-adjacent communities when a heavily loaded cargo plane goes down.

UPS has expressed its support for the NTSB investigation. Bill Moore, President of UPS Airlines, said the company is “working with investigators to determine the root cause” and pledged full cooperation.

What’s Next in the Investigation

1. Detailed Analysis of the FDR/CVR: Investigators will continue to comb through the flight data and cockpit voice recordings for clues into crew actions, emergency warnings, and possible system failures.

   
   

2. Structural Metallurgy: Lab exams of the fractured pylon components will analyze crack propagation, material fatigue life, and whether similar pylons in other aircraft could be at risk.

   
   

3. Maintenance Record Review: Investigators will scrutinize the aircraft’s maintenance history, particularly the recent work done in San Antonio, where ST Engineering maintained the jet.

   
   

4. Fleet-Wide Inspections: Based on findings, both UPS, FedEx, and the FAA may require detailed inspections of pylon structures on similar MD-11/ DC-10 aircraft.

   
   

5. Regulatory Changes: Depending on findings, the FAA and NTSB could propose changes to inspection intervals, aging-component monitoring, and fleet retirement policies.

What It Means for Cargo Aviation

This crash could be a watershed moment for older cargo aircraft, particularly those derived from passenger models like the MD-11. Key implications include:

• Increased Emphasis on Structural Inspections: Aging fleets may be forced to adopt more rigorous inspection protocols for high-stress components.

  
  

• Accelerated Retirement Plans: Cargo operators might accelerate replacement or retirement of legacy aircraft to avoid similar risks.

  
  

• Insurance & Operational Costs: Heightened scrutiny and possible modifications could increase costs for operators, and insurers may reassess underwriting for older jets.

  
  

• Industry Reputation: Cargo aviation’s safety record is under a spotlight. How UPS, FedEx, Boeing (via MD-11 legacy), and regulators respond will influence public and stakeholder trust.