Defense & Military
Leonardo and 2Excel Win RAeS Medal for Excalibur Flight Test Aircraft
Leonardo and 2Excel Aviation were awarded the RAeS Bronze Medal for engineering on the Excalibur Flight Test Aircraft supporting the UK’s sixth-generation combat plane.
This article is based on an official press release from Leonardo.
Leonardo and 2Excel Aviation have been jointly awarded the Royal Aeronautical Society (RAeS) Team Bronze Medal, a prestigious accolade recognizing their rapid engineering achievements on the Excalibur Flight Test Aircraft (FTA). Announced on December 2, 2025, the award highlights the successful transformation of a commercial Boeing 757 into a sophisticated “flying laboratory” designed to support the Global Combat Air Programme (GCAP).
The Excalibur project represents a critical component of the UK’s strategy to develop a sixth-generation combat aircraft, often referred to as Tempest. According to the official announcement from Leonardo, the RAeS medal specifically honors the “extraordinary efforts,” “pace,” and “agility” demonstrated by the joint team in modifying the airframe to host complex military avionics.
This recognition comes shortly after the team successfully completed the first phase of flight trials, which validated the aerodynamic stability of the aircraft while carrying substantial external modifications.
The Excalibur FTA is a retired Boeing 757-200 commercial airliner that has been heavily modified to test the advanced technology required for future combat scenarios. The primary mission of the aircraft is to de-risk the development of the ISANKE & ICS (Integrated Sensing and Non-Kinetic Effects and Integrated Communications Systems) domain.
By utilizing a large commercial airframe, the engineering team can install and test heavy, power-intensive sensors, such as radar, electronic warfare suites, and communications nodes, in a live flight environment long before the actual GCAP fighter prototype takes to the skies. This approach allows for real-time data monitoring by scientists on board the aircraft.
According to the press release and project updates, the award follows the completion of Phase 1 flight trials. These trials focused on safety and aerodynamics, ensuring the aircraft could fly stable with significant structural additions. Key modifications tested during this phase include:
The Royal Aeronautical Society’s decision to award the Team Bronze Medal underscores the effectiveness of the partnership between a major defense prime, Leonardo, and a specialized aviation services SME, 2Excel Aviation. The collaboration is cited by the UK Ministry of Defence as a model for “agile” defense procurement, prioritizing speed and innovation over traditional, slower development cycles.
In the official release, executives from both companies emphasized the unique challenges posed by the program. “This award from the Royal Aeronautical Society recognizes the extraordinary efforts of the team and acknowledges the significant contribution that their work is making to the UK’s future combat air capability. The success of Excalibur reflects the strong partnership between Leonardo and 2Excel. Together, we are helping the programme break new ground while demonstrating pace and agility to meet the ambitious timelines of GCAP.”
, Anthony Todd, Project Chief Engineer, Leonardo
Steve Riley, Executive Director of 2Excel Aviation, noted the historical significance of the engineering pace achieved by the team.
“This programme has presented challenges in the UK aerospace industry that have not been present for decades. The team has met them head-on… demonstrating unparalleled pace throughout.”
, Steve Riley, Executive Director, 2Excel Aviation
The awarding of the RAeS Bronze Medal to the Excalibur team highlights a pivotal shift in how next-generation air dominance platforms are developed. Historically, avionics testing often waited for the availability of a representative military airframe, which could delay systems integration by years. By repurposing a Boeing 757, the GCAP partners are effectively decoupling the sensor development timeline from the airframe development timeline.
We observe that this “digital-first” and “test-early” methodology is essential for meeting the aggressive 2035 service entry target for the Tempest fighter. The ability to fly live sensors in 2025 suggests that the UK and its partners (Italy and Japan) are prioritizing the maturity of the “brain” of the aircraft, the ISANKE & ICS, just as much as the stealth characteristics of the airframe itself.
Leonardo and 2Excel Aviation Awarded RAeS Bronze Medal for Excalibur Flight Test Aircraft
Engineering a Sixth-Generation Testbed
Phase 1 Success and Modifications
Industry Collaboration and Agile Development
AirPro News Analysis
Frequently Asked Questions
Sources
Photo Credit: 2Excel Aviation
Defense & Military
Egypt Becomes Rafale Fighter Jet Component Manufacturer with Dassault Deal
Egypt’s AOI signs a contract with Dassault Aviation to produce Rafale fighter jet wing parts, joining the global aerospace supply chain.
This article is based on an official press release from the Arab Organization for Industrialization (AOI). See the original release for full details.
In a significant development for the Egyptian defense industry, the Arab Organization for Industrialization (AOI) has signed a new industrial cooperation contract with French aerospace giant Dassault Aviation. The agreement, finalized during the Egypt Defence Expo (EDEX) 2025, designates the AOI’s Helwan Military-Aircraft Factory as a certified partner in the global supply chain for the Rafale fighter jet.
According to the official press release from the AOI, the contract was signed in the presence of Lieutenant General Engineer Mokhtar Abdel Latif, Chairman of the AOI, and H.E. Eric Chevallier, the French Ambassador to Cairo. This deal marks a pivotal shift in the relationship between Egypt and Dassault, moving from a traditional buyer-seller dynamic to a strategic manufacturing partnership.
Under the terms of the agreement, Egyptian facilities will, for the first time, manufacture wing components for the Rafale aircraft. This step aligns with Egypt’s broader “Vision 2030” strategy to localize advanced defense technology and reduce reliance on foreign imports.
The core of the agreement focuses on the Helwan Aircraft Factory, which has now been accredited to meet Dassault Aviation’s rigorous quality standards. The AOI statement confirms that the factory will produce specific wing parts for the Rafale, adhering to “Fourth Industrial Revolution” manufacturing standards. This ensures that components produced in Cairo are compatible with Dassault’s global requirements and can be integrated into aircraft destined for international markets.
Anne-Lise Dallut, General Manager of Dassault Aviation in Egypt, praised the capabilities of the Egyptian industrial base.
“The AOI’s factories have met Dassault’s rigorous quality and operational standards, serving as Egypt’s industrial backbone.”
This certification allows the AOI to act as a supply-chain hub, potentially exporting these locally manufactured parts back to France or to other nations operating the Rafale platform.
This contract builds upon years of deepening military and industrial ties between Cairo and Paris. Egypt currently operates one of the largest fleets of Rafale fighter jets outside of France, following major procurement deals signed in 2015 and 2021. The size of this fleet has provided a strong business case for localizing maintenance, repair, and overhaul (MRO) capabilities, as well as component manufacturing. According to reporting by Ahram Online and Daily News Egypt, the partnership has evolved significantly over the last decade. Previous collaborations included the establishment of the AOI School for Applied Technology in Helwan, which trains Egyptian technicians using French curricula to ensure a skilled workforce capable of handling advanced aerospace technologies.
The Dassault agreement is part of a wider trend of French aerospace companies deepening their footprint in Egypt. As noted in reports from Sada Elbalad, the AOI also recently strengthened ties with Safran Aircraft Engines. In late 2024, the AOI Engine Factory was accredited as the sole international center for the overhaul of Larzac engines, which power the Alpha Jet aircraft. These simultaneous developments position Egypt as a regional hub for French defense exports to African and Arab markets.
During the signing ceremony at the Egypt International Exhibition Center, key officials highlighted the economic and strategic importance of the deal.
Lieutenant General Mokhtar Abdel Latif, Chairman of the AOI, emphasized that the agreement reinforces Egypt’s status as a pivotal regional hub for advanced manufacturing. In the official release, he stated that the AOI is committed to increasing local manufacturing content and attracting foreign investment by leveraging its advanced industrial base.
French Ambassador Eric Chevallier echoed these sentiments, noting the strategic nature of the collaboration.
“This partnership supports France’s goal of using Egypt as a hub to boost French exports to neighboring Arab and African nations.”
From Buyer to Maker: A Strategic Leap Economic Implications
Egypt Enters Global Supply Chain for Rafale Fighter Jets with New Manufacturing Deal
Helwan Aircraft Factory to Lead Production
Strategic Context and French-Egyptian Cooperation
Expanding the Industrial Alliance
Official Statements on the Partnership
AirPro News Analysis
The transition from purchasing military hardware to manufacturing components for that hardware represents a critical maturity milestone for Egypt’s defense sector. By securing a role in the supply chain of a flagship platform like the Rafale, the AOI is insulating itself against supply chain disruptions while simultaneously developing high-tech human capital.
Beyond national security, this deal has significant economic potential. Integrating into a global supply chain allows Egypt to generate hard currency through exports. Furthermore, the adoption of “Fourth Industrial Revolution” standards at the Helwan factory will likely have positive spillover effects, raising industrial standards across other sectors of the Egyptian economy.
Sources
Photo Credit: The Arab Organization for Industrialization
Defense & Military
KAI Unveils MAH-1 Helicopter and ALE Drone System at EDEX 2025
KAI presents the MAH-1 attack helicopter with ALE drone at EDEX 2025, targeting Middle East and African defense markets with advanced coastal strike capabilities.
At the Egypt Defence Expo (EDEX) 2025 in Cairo, Korea Aerospace Industries (KAI) officially presented a major evolution in its naval aviation portfolio: the MAH-1 Marine Attack Helicopter paired with an Air Launched Effect (ALE) drone. This unveiling marks the first time South Korea has publicly displayed a dedicated Manned-Unmanned Teaming (MUM-T) system specifically designed for amphibious operations.
According to reporting by Army Recognition, the system is engineered to bolster survivability and extend strike ranges in coastal environments. By debuting this technology in Egypt, KAI appears to be positioning itself as a competitive alternative in the Middle East and African defense markets, utilizing Cairo as a strategic entry point for regional sales.
The centerpiece of the display was the MAH-1, an armed attack variant of the MUH-1 Marineon. The Marineon itself is a derivative of the KUH-1 Surion utility helicopter. Designed to provide close air support (CAS) and anti-armor capabilities for marine landings, the MAH-1 represents a significant step toward indigenous South Korean naval power.
Reports from the event indicate that the helicopter’s development is scheduled to conclude in late 2026, following a maiden flight that occurred in December 2024. The platform features a folding main rotor for shipboard storage and is treated with salt-resistant anti-corrosion coatings to withstand maritime conditions.
Based on data displayed at the exhibition, the MAH-1 boasts a maximum takeoff weight of 8.7 tons and is powered by twin T700-701K turboshaft engines, each generating over 1,800 shaft horsepower. Its dimensions include a length of 19 meters and a width of 6.1 meters.
The aircraft is heavily armed for its support role. It features a chin-mounted 20mm three-barrel turret gun and is capable of carrying a variety of munitions, including Cheongeom (Taipers) anti-tank guided missiles, Mistral air-to-air missiles, and 2.75-inch rockets.
Complementing the manned helicopter is the Air Launched Effect (ALE) drone, a compact unmanned system designed to launch directly from the MAH-1. This “loyal wingman” concept allows the helicopter crew to control the drone via bidirectional data links, extending their sensory reach while keeping the manned aircraft at a safer distance from threats.
According to the specifications provided at EDEX 2025, the ALE model displayed measures approximately 1.2 meters in length with a wingspan of 2.5 meters. It offers an endurance of roughly two hours and a top speed of around 200 km/h. The drone is intended for diverse roles, including Intelligence, Surveillance, and Reconnaissance (ISR), electronic warfare, and potentially loitering munition strikes. “The drone operates ahead of the manned helicopter to detect threats, reducing risk to the crew.”
— Summary of KAI operational concept
This system is part of KAI’s broader “Adaptable Aerial Platform” (AAP) program, which envisions various sizes of air-launched drones compatible with different platforms, including the FA-50 light combat aircraft.
KAI’s decision to unveil this system in Cairo underscores a deliberate strategy to target the Middle East and Africa (MEA) region. Egypt is viewed as a critical hub for this expansion, with KAI leveraging existing defense ties, such as the sale of K9 Howitzers and ongoing discussions regarding the FA-50.
The marketing approach emphasizes industrial cooperation, with proposals for technology transfer and local assembly. This “win-win” model is designed to appeal to nations like Egypt that possess developing amphibious capabilities, such as Mistral-class carriers, but may face budget constraints or export restrictions when seeking top-tier Western platforms.
We observe that the introduction of the ALE represents a critical tactical shift for the MAH-1 platform. By allowing the helicopter to engage targets or gather intelligence “over the horizon,” the system mitigates the risk posed by coastal air defense systems, such as MANPADS, which are a primary threat during amphibious assaults.
Furthermore, this development highlights South Korea’s growing independence in defense technology. By localizing key components like the T700 engines and developing indigenous weapons like the Cheongeom missile, KAI is reducing reliance on foreign suppliers. This autonomy likely makes the platform more attractive to non-aligned nations seeking advanced capabilities without the geopolitical strings often attached to US or European exports.
KAI Unveils Integrated MAH-1 Helicopter and ALE Drone System at EDEX 2025
The MAH-1 Marine Attack Helicopter
Key Specifications and Armament
The “Loyal Wingman”: ALE Drone
Strategic Market Implications
AirPro News Analysis
Sources
Photo Credit: Korea Aerospace Industries
Defense & Military
Pratt & Whitney Secures $1.6B F135 Engine Sustainment Contract
Pratt & Whitney won a $1.6B contract for F135 engine sustainment to support the global F-35 fleet, covering maintenance and engineering through 2026.
This article is based on an official press release from RTX. See the original release for full details.
Pratt & Whitney Secures $1.6 Billion Contract for F-35 Engine Sustainment
RTX business Pratt & Whitney has been awarded a contract worth up to $1.6 billion to provide sustainability support for the F135 propulsion system, the engine that powers the F-35 Lightning II aircraft. Announced on December 2, 2025, the agreement covers maintenance, repair, and engineering support for the global fleet, ensuring operational readiness for the United States and its international allies.
According to the company’s official statement, the award is structured as an Undefinitized Contract Action (UCA). This contracting vehicle allows work to commence immediately while final terms are negotiated, highlighting the Department of Defense’s prioritization of fleet readiness. The contract supports all three variants of the fighter, the F-35A, F-35B, and F-35C, and is expected to run through November 2026.
Scope of Work and Global Operations
The contract encompasses a wide range of critical logistics and engineering services designed to keep the F135 engine operational. Pratt & Whitney stated that the scope includes depot-level maintenance and repair, propulsion system integration, material management, and the replenishment of spare parts. Additionally, the agreement covers software sustainment and engineering support.
Work will be distributed across a substantial domestic and international network. According to RTX, approximately 40% of the work will be performed in East Hartford, Connecticut, with another 21% taking place in Oklahoma City, Oklahoma. Other U.S. performance locations include Florida, Indiana, and Texas.
Reflecting the F-35’s status as a global coalition aircraft, the sustainment efforts will also involve international facilities. The press release lists key locations in Norway, the Netherlands, Japan, Australia, Italy, and the United Kingdom as part of the support network.
“F-35 operators worldwide depend on the F135 for the power and performance their missions demand, and this award helps us maintain readiness rates that enable the warfighter to accomplish their critical missions.”
, Kinda Eastwood, Vice President of F135 Sustainment at Pratt & Whitney
Program Context and Fleet Readiness
This sustainment award follows a period of significant activity for the F135 program. In August 2025, Pratt & Whitney received a $2.8 billion production contract for Lot 18 engines. With over 1,300 production engines delivered to date, the focus has increasingly shifted toward maintaining the aging fleet while simultaneously producing new units.
AirPro News Analysis: The Significance of the UCA
The decision to utilize an Undefinitized Contract Action (UCA) is noteworthy. In defense contracting, a UCA is typically employed when the government’s need for supplies or services is urgent and cannot wait for the lengthy process of finalizing a definitive contract. By authorizing immediate work, the Pentagon is signaling that maintaining F-35 engine readiness is a critical priority that supersedes administrative finality.
This urgency aligns with the current geopolitical landscape. With F-35 assets critical to deterrence strategies in Eastern Europe and the Middle East, any gap in propulsion maintenance could directly impact mission assurance. The UCA mechanism ensures that the flow of spare parts and depot repairs continues uninterrupted.
Long-Term Sustainment and Upgrades
While this $1.6 billion contract addresses immediate sustainment needs through late 2026, the F-35 program faces broader long-term challenges regarding operating costs. Government Accountability Office (GAO) reports from 2024 and 2025 have highlighted that lifetime sustainment costs for the program could reach approximately $1.58 trillion through 2088. As of late 2025, the annual sustainment cost per tail for the F-35A remains significantly above original targets, hovering between $6.6 million and $6.8 million.
Parallel to these sustainment efforts, Pratt & Whitney is executing a separate $1.3 billion contract for the F135 Engine Core Upgrade (ECU). This modernization effort aims to enhance the engine’s power and cooling capabilities to support “Block 4” weapons and sensors. The ECU is currently scheduled for fielding in 2029.
The newly announced sustainment contract serves as a bridge, ensuring the current fleet remains viable and combat-ready while the program navigates these future upgrades and cost-reduction initiatives.
Sources:
- RTX / Pratt & Whitney Press Release
- Government Accountability Office (GAO) Reports (Contextual Data)
Photo Credit: RTX
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