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The company canceled the Sonic Cruiser project and initiated an alternate plan. In the late 1990s, as sales for the popular midsize 767 and 777 slumped, Boeing tested the market waters and introduced a project called the Sonic Cruiser. Built for efficiency, the Dreamliner promised to cut costs significantly in a market where it was increasingly difficult to operate. Conceived with speed in mind, the Sonic Cruiser promised to carry passengers from one place to another 15 percent faster in a completely redesigned, modern aircraft. Your body will need to work harder and expend more energy to carry the extra weight, and chances are you'll sweat a little in the process. And, as we'll see next, manufacturing a one-piece fuselage section out of composites isn't a piece of cake; however, by replacing so much metal with composites, the plane is not only much lighter but is also more aerodynamic. What's more, composites corrode less and are more robust than metal, which reduces the maintenance required for the plane. Although bubbles on a paper-mache piñata may amount to nothing more than aesthetics, for a fuselage they're unacceptable.

In fact, the Dreamliner is the first aircraft in which the wing and fuselage are constructed from composite materials. An added benefit of a stronger composite fuselage structure is that higher pressurization in the passenger cabin is possible. The resulting composite can then be molded before another heating process hardens it into an ultrastrong material. Processing PAN in a series of complicated heating and stretching steps purifies the carbon atoms, which rearrange themselves from ladder to ringlike structures and take the form of long sheets of ribbon. To overcome large-scale carbon fiber processing and taping over complex geometric shapes, new tooling essentially had to be developed and manufactured. You can think of those carbon fibers as the "paper," and those fibers are embedded in a plastic matrix ("paste"), such as an epoxy resin. Following further processing, the fibers are used to reinforce a plastic matrix, which is in a thick, gooey state. The Dreamliner was initially dubbed the 7E7. There was speculation that the 'E' stood for "efficiency" or "environmentally friendly," but Boeing says it stood for nothing more than "eight." The aircraft officially became the Dreamliner following an online public naming contest in 2003, in which around 500,000 votes were cast.