A UPS MD-11 cargo jet in Louisville, Kentucky, suffered a catastrophic engine separation during takeoff on November 4, 2025, caused by structural fatigue in the pylon mounts, forcing investigators to examine maintenance records and DC-10 legacy design flaws, while miraculously no lives were lost, leaving the aviation community shocked and alarmed.

On November 4, 2025, a routine cargo flight from Louisville Muhammad Ali International Airport turned into a nightmare as a UPS McDonnell Douglas MD-11F suffered a catastrophic engine separation just seconds after beginning its takeoff roll.

Airport personnel and witnesses described seeing the left engine and its pylon detach violently from the wing, sending flames and smoke billowing into the sky.

“It was like watching a car engine explode mid-race,” one ground crew member said, shaking his head in disbelief.

The National Transportation Safety Board (NTSB) quickly launched an investigation, focusing on what preliminary reports describe as a severe structural failure in the aircraft’s pylon mounts.

Early examinations of the recovered engine pylon revealed evidence of metal fatigue, specifically cracks on the lugs of the pylon’s aft mount—the critical structure connecting the engine to the wing.

Investigators noted that these fatigue fractures could have been developing over years, unnoticed despite routine maintenance checks.

The MD-11F, a derivative of the DC-10 design dating back decades, has long been scrutinized for its pylon mount structure.

Aviation engineers and historians drew immediate parallels to the 1979 American Airlines Flight 191 disaster, in which a DC-10 lost an engine shortly after takeoff due to damage sustained during maintenance.

In that case, a forklift accident had weakened the engine mount, ultimately causing the tragic crash that claimed 273 lives.

“History might be repeating itself,” an aviation analyst remarked, “but thankfully, the cargo flight meant no passengers were at risk this time.”

Flight data and aerial footage from the day provide a chilling reconstruction.

At V1—the critical takeoff decision speed—the aircraft’s crew initiated liftoff as normal.

Within moments, Vr, the rotation speed, was reached, and the nose lifted.

Witnesses recall hearing an unusual metallic snap just before the left engine tore away, followed by a sudden shift in the aircraft’s balance as the MD-11F struggled to maintain lift on a single engine.

V2, the safe climb speed, became almost irrelevant as the crew immediately focused on controlling the yawing jet and avoiding runway excursion.

Jeff Ostroff, aviation analyst, described in his report that understanding the interplay of V1, Vr, and V2 is crucial for comprehending the dangers inherent in heavy aircraft operations.

“A cargo jet at max takeoff weight is already pushing structural limits,” Ostroff explained.

“Losing a 20-ton engine at that precise moment can create forces that even modern pilots cannot fully counteract, especially when pylon integrity is compromised.”

The NTSB’s ongoing investigation is exploring multiple angles, including the maintenance records of the Louisville hub, potential manufacturing flaws dating back to the DC-10 legacy, and recent inspections of pylon mounts across the MD-11 fleet.

Early reports suggest that while routine checks were conducted, microfractures may have gone undetected—a reminder of the fine line between airworthiness and disaster.

Beyond the technical analysis, the incident has raised questions about regulatory oversight, inspection rigor, and the continued use of aging aircraft designs in cargo operations.

Aviation safety advocates are calling for enhanced monitoring of pylon mounts and other high-stress components, emphasizing that lessons from Flight 191 cannot be ignored.

“We have decades of history showing us where failure points exist,” said one senior engineer.

“Yet here we are, witnessing similar events in 2025.

It’s unnerving, to say the least.”

The Louisville crash has sparked widespread attention within the aviation community, with pilots, engineers, and airline executives scrutinizing the incident for clues about potential systemic risks.

Meanwhile, UPS has pledged full cooperation with the NTSB, confirming that all personnel were unharmed and emphasizing that the cargo onboard was fully insured.

In addition to metal fatigue, experts are also studying aerodynamic forces during the takeoff sequence that may have exacerbated stress on the engine pylon.

The MD-11’s triple-engine design, while efficient, introduces unique weight and balance challenges, especially when one engine suddenly detaches mid-liftoff.

Combined with the historical context of Flight 191, the Louisville incident serves as a stark reminder of the risks inherent in cargo aviation, even for veteran airlines and crews.

The event has prompted a surge in safety discussions globally, as other carriers review their own fleets for potential vulnerabilities.

Aviation forums are buzzing with debate, simulations, and 3D reconstructions showing how even minor structural weaknesses can escalate into dramatic failures under high-stress conditions.

As the investigation continues, the aviation world is left grappling with a haunting question: can history truly be prevented from repeating itself when legacy designs, decades-old engineering, and human factors intersect in high-risk moments? While no lives were lost this time, the dramatic visuals of an engine tearing from a jet mid-air remain seared into the minds of those who witnessed it, a cautionary tale of engineering, vigilance, and the unforgiving physics of flight.