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GE Aerospace and Kratos Develop Next-Gen Turbofan Engines for Defense

GE-Kratos collaboration introduces cost-effective GEK800 and GEK1500 engines for unmanned systems, aligning with DoD’s affordable mass strategy.

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Introduction: The Strategic Shift in Defense Propulsion

The defense industry is undergoing a transformative evolution, driven by the need for affordable, scalable, and high-performance propulsion systems. At the heart of this change is the recent collaboration between GE Aerospace and Kratos Defense & Security Solutions. This partnership, announced in July 2024, represents a concerted effort to meet the growing demand for next-generation small engines tailored for unmanned aerial systems (UAS) and Collaborative Combat Aircraft (CCA).

With adversarial threats becoming more sophisticated and contested environments more prevalent, the U.S. Department of Defense and allied nations are prioritizing “affordable mass”, deploying large numbers of capable but cost-effective systems. The GE-Kratos alliance directly addresses this priority by developing the GEK800 and GEK1500 turbofan engines, designed for both expendable and reusable platforms. This article explores the technical foundations, market dynamics, and strategic implications of this partnership, offering a comprehensive look into the future of autonomous propulsion.

Technical Innovation and Engine Development

GEK800: Compact Efficiency for Expendable Systems

The GEK800 engine represents a significant leap in small-engine design. Derived from Kratos’ earlier KTT650 prototype, the GEK800 delivers 800 pounds of thrust with a compact 36-inch length and 12-inch fan diameter. Unlike traditional turbojets, which prioritize simplicity over efficiency, the GEK800 integrates a high-pressure turbofan architecture that improves specific fuel consumption by up to 30% compared to legacy systems like the Williams F107.

One of the standout features of the GEK800 is its use of 3D-printed components, which reduce part counts and manufacturing costs by approximately 40%. This not only accelerates production timelines but also enhances supply chain resilience. Additionally, the engine employs modular cooling systems, including fuel-cooled bearings and turbine blades, enabling operation at higher temperatures without resorting to expensive materials.

Designed with scalability in mind, the GEK800’s core architecture can be adapted to deliver thrust levels ranging from 800 to 3,000 pounds, making it suitable for a wide range of applications, from loitering munitions to larger CCAs. Testing of the “Build 5” prototype began in mid-2025, with production units expected by early 2026. The projected unit cost of $200,000 to $300,000 positions it as a cost-effective alternative to legacy engines priced in the $1–2 million range.

“By combining GE’s scaling expertise with Kratos’ lean manufacturing, we’re delivering a 50% cost reduction per thrust pound versus legacy engines.” , Amy Gowder, President of GE Aerospace Defense & Systems

GEK1500: Reusability Meets Performance

Building on the GEK800 platform, the GEK1500 engine expands the scope of the partnership into reusable UAS and CCAs. Delivering 1,500 pounds of thrust, the GEK1500 is engineered for extended mission life, with service durations ranging from 500 to 1,000 hours. This is achieved through the integration of nickel-alloy turbine blades, advanced seals, and a dual-spool configuration that enhances altitude performance and thermal management.

Despite its enhanced capabilities, the GEK1500 retains approximately 85% parts commonality with the GEK800. This design philosophy simplifies logistics and maintenance while enabling rapid adaptation across multiple platforms. A prototype demonstration is scheduled for 2026, aligning with the U.S. Air Force’s Increment 2 timeline for CCA deployment.

These innovations are not only technical achievements but also strategic enablers. By offering engines that are both high-performing and cost-effective, GE and Kratos are redefining the economics of propulsion in modern warfare, supporting broader adoption of autonomous systems across allied forces.

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Market Dynamics and Strategic Implications

Global Growth of the Small Engine Market

The global small aircraft engine market, valued at $8 billion in 2023, is projected to grow at a compound annual growth rate (CAGR) of 6.4% through 2030. This growth is fueled by increased demand for military UAS, regional jets, and emerging defense technologies. Microturbine engines, a segment within this market, are expected to grow from $2.3 billion in 2023 to $4 billion by 2033, reflecting a shift toward more efficient turbofan architectures.

Asia-Pacific is emerging as a key player, accounting for 23% of the global market. Countries like India and Japan are investing heavily in indigenous UAS programs, creating significant export opportunities for scalable and modular engine platforms like the GEK800 and GEK1500. These engines’ adaptability and affordability make them attractive to nations seeking to enhance their aerial capabilities without incurring the costs associated with traditional manned systems.

As the market matures, the emphasis is increasingly on engines that offer a balance between performance, cost, and adaptability. The GE-Kratos engine family meets these criteria, positioning the partnership to capture a substantial share of the growing demand for next-generation propulsion systems.

Military Strategy: Embracing Affordable Mass

The U.S. Department of Defense’s 2025 budget underscores a strategic pivot toward “attritable” systems, platforms designed to be low-cost and expendable, yet capable of delivering meaningful operational impact. This approach supports swarming tactics and distributed operations, which are essential in peer conflict scenarios.

The GEK800-powered missile could cost between $500,000 and $1 million, significantly less than the $1.4 million price tag of a Tomahawk Block V. This cost differential allows for broader deployment and tactical flexibility.

Moreover, the engines’ modularity supports multi-role applications, from reconnaissance to strike missions, reducing the logistical burden and enhancing operational efficiency. This versatility is a key factor in meeting the evolving demands of modern warfare.

“With over 20 DoD programs targeting low-cost missiles, we’re positioned to capture 30–40% of this $12 billion market by 2030.” , Eric DeMarco, CEO of Kratos

Competitive Landscape and Industry Challenges

Despite their strong positioning, GE and Kratos face competition from established players like Pratt & Whitney and Honeywell, both of which are developing engines in the sub-3,000 lbf thrust category. However, GE’s vertical integration and Kratos’ agile manufacturing offer a competitive edge, reducing time-to-market by an estimated 6 to 8 months.

The use of advanced manufacturing techniques, such as additive manufacturing and modular design, further enhances the partnership’s ability to respond to market demands quickly. These capabilities are particularly important in a defense landscape where timelines and adaptability can be decisive factors.

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Nevertheless, challenges remain. Regulatory approvals, export controls, and evolving mission requirements will continue to shape the trajectory of small engine adoption. Navigating these complexities will require sustained innovation and strategic alignment with defense stakeholders.

Conclusion: A New Era for Autonomous Propulsion

The collaboration between GE Aerospace and Kratos Defense marks a pivotal moment in the evolution of military propulsion systems. By prioritizing cost, scalability, and modularity, the GEK800 and GEK1500 engines offer a compelling solution to the growing need for affordable mass in modern combat scenarios. These engines are not only technological achievements but also strategic assets that support the broader goals of deterrence and operational flexibility.

Looking ahead, the GE-Kratos partnership is well-positioned to shape the future of autonomous warfare. As demand for UAS and CCA platforms continues to rise, these engines could become foundational components in the next generation of defense systems. With ongoing development and strategic alignment, this alliance has the potential to redefine propulsion economics and operational doctrine for years to come.

FAQ

What is the GEK800 engine used for?
The GEK800 is designed for expendable platforms such as cruise missiles and loitering munitions, offering high efficiency and low production costs.

How does the GEK1500 differ from the GEK800?
The GEK1500 delivers higher thrust and is intended for reusable systems like Collaborative Combat Aircraft. It features enhanced thermal management and longer service life.

Why is the GE-Kratos partnership significant?
The partnership combines GE’s propulsion expertise with Kratos’ low-cost manufacturing to deliver affordable, scalable engines for modern defense needs.

Sources: GE Aerospace, Kratos Defense, U.S. Department of Defense,

Photo Credit: GE Aerospace

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Firehawk Aerospace Expands Rocket Motor Production in Mississippi Facility

Firehawk Aerospace acquires a DCMA-rated facility in Mississippi to boost production of solid rocket motors using 3D-printing technology.

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This article is based on an official press release from Firehawk Aerospace.

Firehawk Aerospace Acquires Mississippi Facility to Scale Rocket Motor Production

On December 19, 2025, Firehawk Aerospace announced a significant expansion of its manufacturing capabilities with the acquisition of a specialized defense facility in Crawford, Mississippi. The Dallas-based defense technology company has secured a 20-year lease on the 636-acre site, which was formerly operated by Nammo Talley.

This acquisition marks a strategic pivot for Firehawk as it moves to address critical shortages in the U.S. defense supply chain. By taking over a facility that is already rated by the Defense Contract Management Agency (DCMA), the company aims to bypass the lengthy construction and certification timelines typically associated with greenfield defense projects. The site will serve as a hub for the full-system integration of solid rocket motors (SRMs), complementing the company’s existing R&D operations in Texas and energetics production in Oklahoma.

Strategic Asset Details

The Crawford facility is located in Lowndes County within Mississippi’s “Golden Triangle” region. According to the company’s announcement, the site is a “turnkey” defense asset designed specifically for handling high-grade explosives and munitions. The infrastructure includes assembly bays protected by one-foot-thick concrete walls and safety “blowout” walls designed to contain accidental detonations.

Because the facility was previously used by Nammo Defense Systems for the high-volume assembly of shoulder-launched munitions, such as the M72 LAW and SMAW systems, it retains the necessary regulatory certifications to allow for rapid operational ramp-up. Firehawk Aerospace CEO Will Edwards emphasized the urgency of this expansion in a statement regarding the deal.

“This acquisition strengthens Firehawk’s ability to address one of the nation’s most urgent defense challenges: rebuilding munition inventories that have been drawn down faster than they can be replaced.”

, Will Edwards, Co-founder and CEO of Firehawk Aerospace

Addressing the “Rocket Motor Crisis”

The acquisition comes at a time when the Western defense industrial base is grappling with a severe shortage of solid rocket motors, which power critical systems like the Javelin, Stinger, and GMLRS missiles. Traditional manufacturing methods, which involve casting propellant in large batches that take weeks to cure, have created production bottlenecks.

Firehawk Aerospace intends to disrupt this model by utilizing proprietary 3D-printing technology to manufacture propellant grains. According to the press release, this additive manufacturing approach reduces production times from weeks to hours. The company has explicitly stated that the new Mississippi facility is being designed to achieve a production tempo of “thousands of rockets per month,” a significant increase over legacy industry standards.

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“While the current industrial base is built to produce thousands of rockets per year, we are building this site… to operate at a much higher production tempo… designing for throughput measured in thousands per month, not years.”

, Will Edwards, CEO

Regional Economic Impact

The expansion is expected to bring skilled jobs to the Golden Triangle region, which is increasingly becoming a hub for aerospace and defense activity. Mississippi Governor Tate Reeves welcomed the investments, noting the dual benefits of economic growth and national security support.

“Their acquisition in Crawford will bring skilled jobs to the region while directly contributing to the production capacity our nation needs.”

, Tate Reeves, Governor of Mississippi

AirPro News Analysis

From R&D to Mass Production: This acquisition signals Firehawk’s transition from a development-focused startup to a volume manufacturer. By securing a pre-rated facility, Firehawk has effectively shaved 2–3 years off its timeline, the period typically required to build and certify a new explosives handling site. This speed is critical given the current geopolitical demand for tactical munitions.

Supply Chain Decentralization: The move also highlights a strategy of decentralization. By distributing operations across Texas (R&D), Oklahoma (Energetics), and now Mississippi (Integration), Firehawk is building a supply chain that may prove more resilient than centralized legacy models. This geographic diversity also allows the company to tap into distinct labor markets and state-level incentives, such as Mississippi’s aerospace initiatives.

Frequently Asked Questions

What is the significance of the DCMA rating?
A DCMA (Defense Contract Management Agency) rating verifies that a facility meets strict Department of Defense quality and safety standards. Acquiring a pre-rated facility allows Firehawk to begin production much faster than if they had to build and certify a new site from scratch.

How does Firehawk’s technology differ from traditional methods?
Traditional solid rocket motors are cast in large batches, a process that requires weeks for the propellant to cure. Firehawk uses 3D-printing technology to print propellant grains, which allows for custom geometries and reduces the manufacturing time to mere hours.

What was the facility used for previously?
The facility was formerly operated by Nammo Talley (now Nammo Defense Systems) for the assembly of shoulder-launched munitions, including the M72 LAW and SMAW systems.

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Photo Credit: Firehawk Aerospace

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20 Years of the F-22 Raptor Operational Capability and Upgrades

Lockheed Martin celebrates 20 years of the F-22 Raptor’s operational service, highlighting its stealth, combat roles, readiness challenges, and modernization.

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Two Decades of the Raptor: Celebrating the F-22’s Operational Milestone

Lockheed Martin has launched a campaign commemorating the 20th anniversary of the F-22 Raptor achieving Initial Operational Capability (IOC). In December 2005, the 27th Fighter Squadron at Langley Air Force Base in Virginia became the first unit to field the fifth-generation fighter, marking a significant shift in global air superiority.

According to the manufacturer’s announcement, the aircraft continues to define the benchmark for modern air combat. In a statement regarding the milestone, Lockheed Martin emphasized the platform’s enduring relevance:

“The F-22 Raptor sets the global standard for capability, readiness, and mission success.”

While the airframe was designed in the 1990s and first flew in 1997, the F-22 remains a central pillar of U.S. air power. The fleet, which consists of approximately 185 remaining aircraft out of the 195 originally built, has evolved from a pure air superiority fighter into a multi-role platform capable of ground strikes and strategic deterrence.

Operational History and Combat Record

Since its operational debut, the F-22 has maintained a reputation for dominance, primarily established through high-end military aircraft exercises rather than direct air-to-air combat against manned aircraft.

Exercise Performance vs. Combat Reality

Data from the U.S. Air Force and independent observers highlights the discrepancy between the Raptor’s exercise performance and its real-world combat engagements. During the 2006 Northern Edge exercise, its first major test after becoming operational, the F-22 reportedly achieved a 108-to-0 kill ratio against simulated adversaries flying F-15s, F-16s, and F/A-18s.

Despite this lethality in training, the aircraft’s combat record is distinct. The F-22 made its combat debut in September 2014 during Operation Inherent Resolve, conducting ground strikes against ISIS targets in Syria. To date, the aircraft has zero confirmed kills against manned enemy aircraft. Its sole air-to-air victory occurred in February 2023, when an F-22 utilized an AIM-9X Sidewinder missile to down a high-altitude Chinese surveillance balloon off the coast of South Carolina.

Stealth Capabilities

The primary driver of the F-22’s longevity is its low observable technology. Defense analysts estimate the Raptor’s Radar Cross Section (RCS) to be approximately 0.0001 square meters, roughly the size of a steel marble. This makes it significantly stealthier than the F-35 Lightning II and orders of magnitude harder to detect than foreign competitors like the Russian Su-57 or the Chinese J-20.

AirPro News Analysis: The Readiness Paradox

While Lockheed Martin’s anniversary campaign highlights “readiness” as a key pillar of the F-22’s legacy, recent Air Force data suggests a more complex reality regarding the fleet’s health.

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We note that maintaining the world’s premier stealth fighter comes at a steep logistical cost. According to data published by Air & Space Forces Magazine regarding Fiscal Year 2024, the F-22’s mission capable (MC) rate dropped to approximately 40%. This figure represents a decline from roughly 52% in the previous fiscal year and indicates that, at any given time, fewer than half of the Raptors in the inventory are flyable and combat-ready.

This low readiness rate is largely attributed to the fragility of the aircraft’s stealth coatings and the aging avionics of the older airframes. The Air Force has previously attempted to retire 32 older “Block 20” F-22s used for training to divert funds toward newer programs, though Congress has blocked these efforts to preserve fleet numbers. The contrast between the jet’s theoretical dominance and its logistical availability remains a critical challenge for planners.

Modernization and Future Outlook

Contrary to earlier projections that might have seen the F-22 retired in the 2030s, the Air Force is investing heavily to keep the platform viable until the Next Generation Air Dominance (NGAD) fighter comes online.

The ARES Contract and Upgrades

In 2021, the Air Force awarded Lockheed Martin a $10.9 billion contract for the Advanced Raptor Enhancement and Sustainment (ARES) program. This decade-long modernization effort aims to update the fleet’s hardware and software.

According to budget documents for Fiscal Year 2026, the “Viability” upgrade package includes several key enhancements:

  • New Stealth Tanks: The development of low-drag external fuel tanks and pods designed to extend the aircraft’s range without compromising its radar signature.
  • Infrared Search and Track (IRST): The integration of new sensors capable of detecting heat signatures, a critical capability for engaging enemy stealth fighters that may not appear on radar.
  • Manned-Unmanned Teaming: Software upgrades intended to allow F-22 pilots to control “Collaborative Combat Aircraft”, autonomous drone wingmen, in future operational environments.

These investments suggest that while the F-22 is celebrating its past 20 years, the Air Force intends to rely on its capabilities well into the next decade.

Sources

Sources: Lockheed Martin, U.S. Air Force

Photo Credit: Lockheed Martin

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U.S. Navy Zero-G Helmet System Completes Critical Design Review

Collins Elbit Vision Systems completes design review for the Zero-G Helmet Display, reducing pilot weight load and enhancing safety for Navy aircraft.

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This article is based on an official press release from Collins Elbit Vision Systems (RTX).

Critical Design Review Completed for Navy’s Next-Gen Helmet

Collins Elbit Vision Systems (CEVS), a joint venture between RTX’s Collins Aerospace and Elbit Systems of America, has officially announced the completion of the Critical Design Review (CDR) for the Zero-G Helmet Mounted Display System+ (HMDS+). This milestone, finalized on December 12, 2025, marks a pivotal step in the U.S. Navy’s Improved Joint Helmet-Mounted Cueing System (IJHMCS) program.

The successful CDR effectively freezes the system’s design, confirming that the helmet meets the Navy’s rigorous requirements for safety, performance, and platform integration. With the design locked, the program now transitions into the airworthiness testing and integration phase, bringing the system closer to deployment aboard the F/A-18E/F Super Hornet and EA-18G Growler fleets.

According to the press release, the Zero-G HMDS+ is engineered to address long-standing physiological challenges faced by naval aviators while introducing “6th-generation” digital capabilities to existing 4.5-generation aircraft.

Technical Leap: The Zero-G HMDS+

The Zero-G HMDS+ represents a significant departure from legacy analog systems. While previous iterations required pilots to physically attach heavy Night Vision Goggles (NVGs) for low-light operations, the new system integrates digital night vision directly into the visor. This integration streamlines cockpit operations and reduces the physical burden on the aircrew.

Weight Reduction and Pilot Safety

A primary driver for the Zero-G’s development is the reduction of head-borne weight. High-G maneuvers in fighter aircraft place immense strain on a pilot’s neck and spine, a hazard exacerbated by heavy, unbalanced legacy helmets. CEVS reports that the Zero-G system is more than 25 percent lighter than current market alternatives. Its name is derived from its optimized center of gravity, designed to minimize fatigue and long-term injury risks.

Capt. Joseph Kamara, the U.S. Navy Program Manager for Naval Aircrew Systems (PMA-202), emphasized the safety implications of the new design in a statement:

“Aircrew health and safety is our number one priority. The Zero-G being integrated through our IJHMCS program promises to relieve aircrew of neck and back strain and greatly improve ejection safety.”

Advanced Display Capabilities

Beyond ergonomics, the helmet utilizes a binocular waveguide display system. Unlike monocular reticles used in older models, this technology projects high-definition color symbology and video into both eyes, creating a fully immersive 3D view of the battlespace. The system is capable of “sensor fusion at the edge,” processing mission data and weapon information directly on the helmet to act as a primary flight instrument.

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Luke Savoie, President and CEO of Elbit Systems of America, highlighted the strategic necessity of this upgrade:

“Zero-G is providing sensor fusion at the edge… As fighter aircraft level-up, the HMDs of those systems need to as well.”

Program Timeline and Deployment

The Zero-G HMDS+ program has moved rapidly since CEVS was awarded a $16 million contract by the U.S. Navy in September 2023 for development and test support. Following the successful CDR in December 2025, the program is scheduled to undergo flight testing and Avionics integration throughout 2026 and 2027.

The U.S. Navy projects Initial Operational Capability (IOC) for the system in 2027. Once fielded, it is expected to equip aviators across the entire fleet of U.S. Navy and Royal Australian Air Force Super Hornets and Growlers, totaling more than 750 aircraft.

AirPro News Analysis

The completion of the CDR signals a critical maturity point for the Navy’s effort to modernize the human-machine interface in its tactical fleet. While much industry attention is focused on future platforms like NGAD (Next Generation Air Dominance), the Zero-G program illustrates the military’s commitment to maintaining the lethality and survivability of its existing backbone fleet.

By adapting technology originally matured for the F-35 Gen III helmet, CEVS is effectively retrofitting advanced situational awareness tools onto older airframes. This approach not only extends the combat relevance of the Super Hornet but also addresses the acute retention issue of pilot physical health. The shift to digital night vision and balanced weight distribution suggests that the Navy views pilot longevity as a critical component of fleet readiness.

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Photo Credit: RTX

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