Defense & Military
HAL Receives Fourth GE F404 IN20 Engine for Tejas Fighter Program
HAL receives fourth GE-F404-IN20 engine, advancing India’s Tejas Mark 1A fighter and defense self-reliance amid supply chain challenges.
The delivery of the fourth GE-F404-IN20 engine to Hindustan Aeronautics Limited (HAL) marks a pivotal moment in India’s ongoing quest for aerospace self-reliance and the modernization of its air defense capabilities. This event is part of a $716 million contract signed in 2021 for 99 engines and reflects the gradual progress made despite significant Supply-Chain disruptions that have affected the Light Combat Aircraft (LCA) Tejas Mark 1A program. As the Indian Air Force (IAF) faces the pressing need to replace aging MiG-21 squadrons, the Tejas project and the timely delivery of these engines are increasingly important for both operational readiness and the country’s broader defense Manufacturing ambitions.
HAL expects to receive a total of 12 engines by the end of the current financial year, with plans to ramp up production to 30 aircraft annually by 2026-27. This milestone is not only a technical achievement but also a strategic step toward reducing India’s dependence on foreign defense imports. The broader implications extend to India’s “Make in India” initiative, rising defense budgets, and the country’s evolving role in global aerospace supply chains amid widespread industry disruptions.
The Light Combat Aircraft (LCA) program is one of India’s most ambitious indigenous defense initiatives, with roots tracing back to the 1980s. The goal was to replace the IAF’s aging fleet of Soviet-era fighters and reduce reliance on foreign suppliers, a strategic vulnerability highlighted by decades of arms import challenges. The Tejas program’s development journey reflects the complexities and persistence required for indigenous aerospace advancement, especially in a sector as sophisticated as military aviation.
The GE F404 engine family was chosen for the Tejas after extensive collaboration between General Electric and India’s Aeronautical Development Agency, starting in the 1980s. The engine was formally selected in 2004, following rigorous evaluation of available options and India’s long-term strategic objectives. This partnership laid the groundwork for gradual technology transfer and knowledge sharing, crucial for the program’s maturation.
Initial procurement included 10 F404-F2J3 engines for technology demonstrators and prototypes, followed by additional contracts in 2004 and 2007 for 17 and 24 engines respectively. By 2016, 75 engines (both F2J3 and IN20 variants) had been delivered, supporting the transition from development to operational service. As of mid-2025, the IAF operates two Tejas Mark 1 squadrons, with 38 of 40 ordered aircraft delivered and the final two trainers expected soon. This operational status signals the program’s steady progress and its role in filling the capability gap left by the recent retirement of the MiG-21 squadrons.
“The retirement of the MiG-21 after more than six decades of service underscores the urgency and significance of the Tejas program for India’s air defense needs.”
The F404-GE-IN20 engine is a highly advanced adaptation of GE’s proven F404 family, designed to meet the specific requirements of the Tejas Mark 1A. This variant is the highest thrust version, producing up to 85 kN (19,000 lbf) with afterburner, compared to the baseline’s 78.7 kN. It also features increased airflow (153 lb/sec vs. 146 lb/sec) and a higher pressure ratio (28:1 vs. 26:1), contributing to improved thrust and fuel efficiency.
Advanced materials such as single-crystal turbine blades and ceramic matrix composites, along with enhanced cooling systems, enable reliable performance in India’s hot and humid conditions. The Full Authority Digital Engine Control (FADEC) system, adapted from GE’s F414 engine, provides precise digital control, optimizing fuel efficiency and enabling predictive maintenance through in-flight engine condition monitoring. This reduces unscheduled maintenance and increases fleet availability.
The F404-IN20’s combat-proven heritage, over 13 million flight hours on platforms like the F/A-18 Hornet, offers confidence in its reliability and performance. The engine’s six-module architecture ensures ease of maintenance and component interchangeability, while its unrestricted throttle response and afterburner stability provide the responsive power required for modern air combat. These features, combined with the Tejas’s advanced Avionics, position the Mark 1A as a competitive platform in the global fighter market. “The F404-IN20 engine’s unrestricted performance, advanced materials, and digital controls make it a cornerstone of the Tejas Mark 1A’s operational capabilities and India’s defense self-reliance efforts.”
The F404-IN20 program has faced significant supply chain disruptions, reflecting broader vulnerabilities in the global aerospace sector. The original 2021 Contracts for 99 engines was delayed by nearly two years due to issues such as the closure and subsequent restart of GE’s production line, and problems with a South Korean component supplier. These disruptions mirror a 35% increase in aerospace supply chain disruptions globally between 2023 and 2024.
Restarting the GE production line in Boston after a five-year hiatus required coordination with suppliers, workforce retraining, and quality system revalidation. The South Korean supplier issue highlighted the risks of single-source dependencies in complex supply chains, where lead times for critical components can extend to 18-24 months. The recovery plan now targets the delivery of 12 engines in the current financial year, with a steady rate of 20 engines annually from 2026 onward.
These supply chain issues have affected HAL’s production planning, with several Tejas Mark 1A airframes ready but awaiting engines. The mismatch between aircraft readiness and engine availability has led to inventory and resource allocation challenges. Such disruptions not only delay deliveries but also increase costs and can impact the IAF’s operational readiness. Broader industry data indicates that about 30% of aerospace companies have experienced cost impacts of 1% to over 5% due to supply chain and regulatory challenges.
The F404-IN20 engine program is a major financial undertaking for India, with the initial $716 million contract likely to be followed by an additional Orders for 113 engines, potentially bringing the total value to $1.7 billion. This investment is a cornerstone of India’s broader defense modernization strategy, which has seen the defense budget rise from ₹2.53 lakh crore in 2013-14 to ₹6.81 lakh crore in 2025-26.
Beyond procurement, the program supports India’s goal of building a robust indigenous defense industry. Defense production reached ₹1.27 lakh crore in 2023-24, a 174% increase from a decade earlier. The Ministry of Defence has prioritized domestic contracts, with 177 of 193 contracts in 2024-25 awarded to Indian industry. The Tejas program’s increasing indigenous content, targeted to exceed 70%, and the establishment of local maintenance and overhaul facilities further reduce reliance on foreign suppliers.
The F404-IN20’s improved fuel efficiency and longer maintenance intervals (over 1,000 flight hours between overhauls) are expected to yield operational savings of 15-20% compared to previous engines. Additionally, the program lays the groundwork for technology transfer in future projects, such as the F414 engine for the Tejas Mark 2 and the Advanced Medium Combat Aircraft (AMCA) program. The Tejas’s export potential, supported by HAL’s design and software customization capabilities, could further enhance India’s defense sector revenues.
“India’s defense production has increased by 174% in a decade, and the Tejas program’s growing indigenous content exemplifies the country’s shift toward self-reliance and global competitiveness.”
HAL’s production strategy for the Tejas Mark 1A involves a distributed model, with manufacturing lines in Bangalore and Nashik, and significant contributions from private sector partners. This approach aims to achieve the target of 30 aircraft annually by 2026-27, a significant scale-up from current rates. Private companies like Alpha Tocol Engineering Services and VEM Technologies are supplying major airframe components, increasing the resilience and capacity of the supply chain.
The engine supply schedule remains the primary constraint on production scaling. HAL’s plans are predicated on GE delivering 12 engines in 2025-26 and 20 engines annually thereafter. The IAF’s long-term procurement plan for 352 Tejas aircraft (including Mark 1A and Mark 2 variants) provides a stable demand base, supporting investment in capacity expansion and technology upgrades. The success of the Mark 1A program will influence the development of the Tejas Mark 2 (with F414 engines) and the AMCA, India’s planned fifth-generation stealth fighter. Lessons learned from current supply chain and production challenges will inform future projects. Additionally, the export potential of the Tejas, enabled by HAL’s customization capabilities, could open new markets and further justify Investments in production capacity.
The F404-IN20 program’s challenges reflect systemic issues in the global aerospace supply chain. Disruptions increased by 35% from 2023 to 2024, with factory fires and labor strikes (notably the Boeing machinists’ strike) among the leading causes. The aerospace industry’s reliance on single-source suppliers and just-in-time inventory practices has heightened vulnerability to such events.
Labor disruptions surged by 33% in 2024, with the Boeing strike alone costing $9.7 billion and causing significant production delays. Material shortages, especially of steel and titanium, and regulatory compliance requirements have further constrained production. At least one-third of aerospace companies report being unprepared for planned production rate increases due to capacity and workforce limitations.
To mitigate these risks, nearly a quarter of companies are adopting regionalized supply chains, balancing global sourcing with local redundancy. Regulatory compliance, particularly related to sustainability, adds further complexity and cost. The lessons from the F404-IN20 supply chain disruptions underscore the need for greater resilience, redundancy, and strategic planning in both Indian and global aerospace manufacturing.
“Aerospace supply chain disruptions rose 35% in a single year, highlighting the need for resilience and strategic risk management in defense manufacturing.”
The delivery of the fourth GE-F404-IN20 engine to HAL is more than a technical milestone; it symbolizes India’s determined pursuit of defense self-reliance and the modernization of its aerospace capabilities. The journey has been marked by significant challenges, particularly in supply chain management, but also by steady progress in indigenous production, technology transfer, and strategic partnership building.
As India continues to expand its defense manufacturing base and aims for ambitious production targets, the lessons learned from the F404-IN20 program will shape future projects and enhance the country’s position in the global aerospace sector. The successful integration of public and private sector capabilities, combined with a focus on resilience and innovation, will be crucial for sustaining this momentum and achieving long-term strategic objectives.
Q: What is the significance of the F404-IN20 engine for the Tejas Mark 1A? Q: Why were there delays in engine deliveries? Q: How does the Tejas program support India’s defense manufacturing goals? Q: What are the future prospects for the Tejas and its engines?
HAL Receives Fourth GE-F404-IN20 Engine: Critical Milestone in India’s Indigenous Fighter Aircraft Program
Background and Historical Context of the Tejas Program
The F404-IN20 Engine: Technical Specifications and Strategic Importance
Supply Chain Challenges and Delivery Timeline Analysis
Financial and Strategic Implications for India’s Defense Sector
Future Outlook and Production Capacity Planning
Global Aerospace Supply Chain Context and Industry Challenges
Conclusion
FAQ
A: The F404-IN20 is a high-thrust, advanced variant of GE’s F404 engine, offering improved performance, reliability, and digital controls. It is critical for the operational capabilities of the Tejas Mark 1A and supports India’s drive for defense self-reliance.
A: Delays were caused by global supply chain disruptions, including the closure and restart of GE’s production line and issues with a South Korean component supplier. These reflect broader challenges in the aerospace industry.
A: The program increases indigenous content, builds local manufacturing and maintenance capabilities, and supports technology transfer. It is a key part of India’s strategy to reduce reliance on foreign imports and grow its defense sector.
A: Future prospects include expanded production for the IAF, development of the more advanced Tejas Mark 2, potential exports, and ongoing technology transfer initiatives with GE and other partners.
Sources
Photo Credit: The Economic Times
Defense & Military
France Confirms Next-Generation Nuclear Aircraft Carrier Program
France will build the PANG, a new nuclear-powered aircraft carrier to replace Charles de Gaulle by 2038, featuring EMALS and advanced fighters.
This article summarizes reporting by Reuters.
French President Emmanuel Macron has officially confirmed that France will proceed with the construction of a new nuclear-powered aircraft carrier, intended to replace the aging Charles de Gaulle by 2038. Speaking to French troops stationed in Abu Dhabi on Sunday, December 21, Macron outlined the decision as a critical step in maintaining France’s status as a global maritime power.
According to reporting by Reuters, the President emphasized the necessity of naval strength in an increasingly volatile world. The announcement, made from a strategic military base in the United Arab Emirates, underscores Paris’s commitment to projecting power beyond Europe, particularly into the Indo-Pacific region.
The new vessel, known as the Porte-Avions de Nouvelle Génération (PANG), represents a significant technological and industrial undertaking. It aims to ensure France remains the only European Union nation capable of deploying a nuclear carrier strike group, a capability central to Macron’s vision of European “strategic autonomy.”
The PANG program calls for a vessel that will significantly outclass its predecessor in size, power, and capability. While the Charles de Gaulle displaces approximately 42,500 tonnes, defense reports indicate the new carrier will be the largest warship ever built in Europe.
Based on technical data cited by naval analysts and French media, the new carrier is expected to displace between 75,000 and 80,000 tonnes and measure over 300 meters in length. It will be powered by two K22 nuclear reactors, providing nearly double the power output of the current fleet’s propulsion systems.
A key feature of the new design is the integration of the Electromagnetic Aircraft Launch System (EMALS), technology currently used by the U.S. Navy’s Gerald R. Ford-class carriers. This system replaces traditional steam catapults, allowing for the launch of heavier Military-Aircraft and Drones while reducing mechanical stress on the airframes.
The air wing is expected to include: “The decision to launch this vast programme was taken this week,” Macron told troops, highlighting the strategic urgency of the project.
The choice of Abu Dhabi for this major announcement was likely calculated. The UAE hosts a permanent French naval base, serving as a logistical hub for operations in the Indian Ocean and the Persian Gulf. By unveiling the PANG program here, Paris is signaling its intent to protect its extensive Exclusive Economic Zone (EEZ) in the Indo-Pacific and counter growing naval competition in the region.
The ambitious project comes at a time of significant domestic financial strain. Reports estimate the program’s cost will exceed €10 billion ($10.5 billion). With France facing a projected public deficit of over 6% of GDP in 2025 and a minority government navigating a hung parliament, the allocation of such vast funds has drawn criticism from opposition parties.
Critics argue the funds could be better utilized for social services or debt reduction. However, supporters and industry stakeholders note that the project will sustain thousands of jobs at major defense contractors like Naval Group and Chantiers de l’Atlantique, as well as hundreds of smaller suppliers.
The Paradox of Autonomy: While President Macron champions “strategic autonomy,” the ability for Europe to act independently of the United States, the PANG program reveals the practical limits of this doctrine. By adopting the U.S.-designed EMALS catapult system, the French Navy ensures interoperability with American supercarriers but also cements a long-term technological dependence on U.S. suppliers. This decision suggests that while France seeks political independence, it recognizes that high-end naval warfare requires deep technical integration with its NATO allies.
When will the new carrier enter service? Why is France choosing nuclear Propulsion? How much will the project cost? Will other European nations use this carrier? Sources: Reuters
France Confirms Launch of Next-Generation Nuclear Aircraft Carrier Program
A New Giant of the Seas
Technical Specifications and Capabilities
Strategic Context and Geopolitical Signals
Budgetary and Political Headwinds
AirPro News Analysis
Frequently Asked Questions
Construction is slated to begin around 2031, with sea trials expected in 2036. The vessel is scheduled to be fully commissioned by 2038, coinciding with the retirement of the Charles de Gaulle.
Nuclear propulsion offers unlimited range and the ability to sustain high speeds for long durations without refueling. It also allows the ship to generate the massive amounts of electricity required for next-generation sensors and electromagnetic catapults.
Current estimates place the cost at over €10 billion ($10.5 billion), though complex defense programs often see costs rise during development.
While the carrier is a French national asset, it is designed to support European security. However, it will primarily host French naval aviation, with potential for interoperability with U.S. and allied aircraft.
Photo Credit: U.S. Navy photo by Mass Communication Specialist 3rd Class Bela Chambers
Defense & Military
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.
This article is based on an official press release from Firehawk Aerospace.
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.
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
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. “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
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
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.
What is the significance of the DCMA rating? How does Firehawk’s technology differ from traditional methods? What was the facility used for previously?
Firehawk Aerospace Acquires Mississippi Facility to Scale Rocket Motor Production
Strategic Asset Details
Addressing the “Rocket Motor Crisis”
Regional Economic Impact
AirPro News Analysis
Frequently Asked Questions
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.
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.
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.Sources
Photo Credit: Firehawk Aerospace
Defense & Military
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.
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.
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.
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.
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.
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. 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.
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.
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:
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: Lockheed Martin, U.S. Air Force
Two Decades of the Raptor: Celebrating the F-22’s Operational Milestone
Operational History and Combat Record
Exercise Performance vs. Combat Reality
Stealth Capabilities
AirPro News Analysis: The Readiness Paradox
Modernization and Future Outlook
The ARES Contract and Upgrades
Sources
Photo Credit: Lockheed Martin
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