Plane Detours Due to Windshield Cracks

Evanne Evans, 08 June 2025

An Airbus A330-200 passenger plane carrying 188 passengers and 12 crew members departed from Heathrow Airport for Detroit in the U.S, but had to return to the London-based airport shortly after takeoff due to a cracked windscreen.

The plan landed safely, and no one was injured. However, there were disruptions to passengers and airport schedules, as some travelers were accommodated in hotels until their next flight became available, while others were able to book onto flights later the same day.

In 2024, a United Airlines Boeing 737-800 was diverted to Denver after a windshield crack was discovered during the flight. Similarly, an American Airlines Boeing 777, on its way to Madrid, Spain, made an emergency landing in Boston after a crack appeared on the windscreen mid-flight. The Alert 2 emergency occurred less than two hours into the journey, as confirmed by the Massachusetts State Police, and again, no injuries were reported.

Aircraft windscreens, also known as windshields, must withstand extreme temperatures and pressures whilst continuing to allow for visibility and therefore undergo regular maintenance inspections. Windshields are comprised of layers of material such as glass, acrylic and plastics, along with an interlayer heating system for de-icing and anti-fogging, that are bonded together.

Various environmental and negligence issues can cause damage to windshields, including chips and delamination, bubbles or screen scratches, fogging due to issues with the internal heating system, broken fasteners that attach the body of the plane, and bird strikes.

Bird strike damage can cause significant cracks in windshields, but the extent of repairs depends on the size of the bird. Airports are often located near open fields, wetlands, or coastlines—habitats that attract a diverse range of birds and other wildlife. Over 90% of bird strikes happen at altitudes below 3,000 feet because birds are most active during dawn and dusk periods, commonly referred to as “rush hours” in the aviation industry.