NAL hands over AMCA’s carbon composite flaperon test box to DRDO’s ADA

The Aeronautical Development Agency (ADA), in collaboration with CSIR-NAL, has successfully designed and developed a cutting-edge Flaperon Structural Assembly for the Advanced Medium Combat Aircraft (AMCA) program, India’s to-be 5th generation stealth fighter jet, achieving a breakthrough in composite technologies.

CSIR-NAL handed over the jointly developed IM7 carbon composite based flaperons for the AMCA Project to ADA. | Image: NAL

This milestone was marked by the completion of the AMCA’s Flaperon Test Box Assembly on October 5, 2023, a significant day for the Indian aerospace industry. According to sources from the National Aerospace Laboratories director's office, the assembly has been officially handed over, symbolising a milestone in this collaborative effort.

ADA gets a breakthrough in composite technologies

As per NAL, the project utilised 'state-of-the-art' intermediate modulus grade carbon composites (IM7), a futuristic material with an exceptional strength-to-weight ratio. ADA and NAL worked together to study robust, mid-level carbon materials.

The flaperon assembly, a critical component of the AMCA, incorporates co-cured technology, a cutting-edge approach to composite fabrication. This achievement is set to revolutionise the design and production of medium-weight combat aircraft, as the high-strength carbon composites promise a reduction in overall weight, according to NAL's official statement.

Metal-cutting for AMCA 

Last year, R Madhavan, the Chairman and Managing Director of Hindustan Aeronautics Limited, marked the onset of AMCA’s technology demonstrator’s development by launching the 'Metal Cutting for Titanium Bulkhead of AMCA aircraft' at the Aircraft Manufacturing Division, Nashik, on July 13. The event was also attended by AK Ghosh, Project Director (AMCA) at ADA, along with senior officers from DMRL, ADA, and other key government agencies.

HAL along with officials from ADA and DRDO ahead of AMCA's metal-cutting. | Image: X

Future prospects for AMCA

Looking ahead, the first prototype rollout of the AMCA is anticipated in the near future, following HAL's plan to commence production between 2026-28. However, full-fledged production operations are slated to kick off in 2029, as per a prior statement from HAL.

In parallel, the AMCA program would in the future see the augmentation of an indigenous 125kN thrust engine. DRDO would develop this in a joint venture with another firm. As of now, Rolls Royce and Safran are leading the choice of a JV with DRDO. Indian Defence Minister Rajnath Singh also visited the Safran facilities during his France visit on October 11, 2023.

Defence State Minister Ajay Bhatt, last year, highlighted the strategic importance of the AMCA program, emphasising its cost-effectiveness in comparison to similar fifth-generation aircraft.

“The process for obtaining Cabinet Committee on Security’s (CCS) approval for the design and prototype development of the Advanced Medium Combat Aircraft (AMCA) has been initiated. 5th Generation fighter aircraft, due to very special features, are costlier than 4th Generation fighter aircraft. Since AMCA is an indigenous 5th Generation aircraft, it is less costly than similar aircraft available outside,” stated the State Defence Minister.

The AMCA project is India's second foray into fifth-generation fighter aircraft, following the not-so-satisfactory collaboration with Russia on the SU-57 Felon program, and it highlights India’s ‘Atma Nirbhar’ initiative in pursuit of self-reliance.