Defense & Military
NAVAIR V-22 Review Highlights 32 Fixes and Safety Risks
NAVAIR’s review finds rising safety risks in V-22 program, mandates 32 fixes including triple-melt steel gearboxes by 2026 for full flight operations.

NAVAIR V-22 Review: “Cumulative Risk” Warning and 32 Mandatory Fixes
Naval Air Systems Command (NAVAIR) released the findings of its comprehensive review of the V-22 Osprey program on December 12, 2025. While the report reaffirmed the platform’s airworthiness under current strict operational controls, it delivered a stark assessment of the fleet’s safety culture, identifying a “cumulative risk posture” that has grown unchecked since the Military-Aircraft was first fielded.
The review, which covers variants flown by the Air Force (CV-22), Marine Corps (MV-22), and Navy (CMV-22), was triggered by a series of mishaps, including the catastrophic November 2023 crash of an Air-Forces CV-22B off the coast of Japan that resulted in the deaths of eight airmen. According to the findings, the program must implement 32 distinct recommendations to address systemic failures in safety, maintenance, and supply chain management.
Systemic Issues and “Cumulative Risk”
The core finding of the NAVAIR report is that safety risks within the V-22 program have been allowed to accumulate rather than diminish over time. In mature aircraft programs, risk profiles typically decrease as the platform ages and operators gain experience. However, the review concludes that the V-22’s risk profile has increased.
Data released in the report highlights a significant disparity in how quickly the V-22 program addresses critical issues compared to other naval aviation platforms:
- Resolution Time: Critical safety and technical issues on the V-22 have gone unresolved for an average of 10 years.
- Comparison: The average time to resolve similar risks in other naval aviation platforms is approximately six years.
- Risk Ranking: The V-22 currently holds the second-highest number of “catastrophic” risk factors across all Naval Aviation platforms.
The review suggests that these delays were exacerbated by “siloed operations,” criticizing the lack of coordination between the Navy, Marine Corps, and Air Force. Differing safety standards and maintenance procedures among the services contributed to a fragmented approach to fleet safety.
Material Failure Confirmed
The report definitively confirmed the cause of the November 2023 crash. Investigators identified a material failure in the proprotor gearbox (PRGB). Specifically, “inclusions”, impurities in the steel alloy gears, led to cracking and eventual failure of the component. This finding validates earlier concerns regarding the quality control of critical drive system components.
Technical Overhaul and “Triple-Melt” Steel
To address the material failures identified in the gearbox, the program is undertaking a significant Manufacturing shift. According to the review, the program is transitioning to a “triple-melt” (VIM-VAR-VAR) forging process for critical gear components.
This advanced manufacturing technique is designed to remove impurities from the alloy. NAVAIR estimates that this process will reduce the risk of inclusions by approximately 85% to 90%. The timeline for these technical upgrades is as follows:
- Summer 2025: Depot-level installation of the new “triple-melt” gears is scheduled to begin.
- 2026: Unrestricted flight operations are expected to resume, pending fleet-wide installation.
In addition to the gearbox metallurgy, the program is deploying a redesigned input quill assembly to mitigate “hard clutch engagements,” a historic mechanical issue for the Osprey. The fleet will also see the deployment of the Osprey Drive System Safety and Health Instrumentation (ODSSHI), a network of advanced sensors capable of monitoring vibration and gear health in real-time to alert crews of potential failures.
Operational Status and Restrictions
Despite the technical roadmap, the V-22 fleet remains under significant operational restrictions as of December 12, 2025. While the aircraft is deemed airworthy, the review mandates that flights generally remain within 30 minutes of a suitable divert airfield. This restriction ensures that pilots can land quickly if a mechanical issue arises.
Furthermore, the program has established a strict flight-hour threshold for proprotor gearboxes. Any aircraft exceeding this threshold must undergo rigorous inspections or component replacement before returning to flight.
“When the V-22 Enterprise does not actively manage risks… the risks compound, increasing the likelihood of a catastrophic event.”
— Vice Adm. John E. Dougherty, NAVAIR Commander
Organizational Changes
Beyond technical fixes, the review calls for a restructuring of how the V-22 program is managed. A key recommendation is the establishment of a joint “Readiness and Safety Steering Board.” This body will be responsible for enforcing uniform Standards across the Air Force, Navy, and Marine Corps, reporting annually to top leadership to ensure accountability.
The report also outlines a shift toward a “proactive safety system.” This new approach aims to identify and fix mechanical issues before they lead to mishaps, moving the program away from the reactive posture that characterized the last decade.
AirPro News Analysis
The NAVAIR review represents a pivotal moment for the V-22 Osprey, a platform that has long been defined by its revolutionary tiltrotor capability and its troubled safety record. The admission of a “cumulative risk posture” is significant; it suggests that the bureaucracy surrounding the aircraft became desensitized to warning signs over the last decade.
While the technical solution, “triple-melt” steel, appears robust, the timeline suggests that the V-22 fleet will remain operationally hamstrung for at least another year. The challenge for NAVAIR will not just be manufacturing new gears, but enforcing the cultural changes required to break down the silos between the three services. If the new Safety Steering Board cannot enforce uniform standards, the technical upgrades may only solve part of the equation.
Frequently Asked Questions
- Is the V-22 Osprey currently flying?
- Yes, but with restrictions. As of December 2025, the aircraft is restricted to flying within 30 minutes of a suitable divert airfield.
- What caused the November 2023 crash?
- The review confirmed the crash was caused by a material failure in the proprotor gearbox due to impurities (inclusions) in the steel alloy gears.
- When will the fleet return to full operations?
- Unrestricted flight operations are not expected to resume until 2026, following the installation of upgraded gearbox components.
Sources
Photo Credit: NAVAIR
Defense & Military
Bombardier and BAE Systems Sign MOU for Combat Air Programs
Bombardier and BAE Systems signed an MOU on Oct 28, 2026, to explore next-generation combat air collaboration.

Bombardier and BAE Systems have signed a strategic Memorandum of Understanding (MOU) to explore joint development of industrial and technology capabilities for next-generation combat air programs.
Announced in a press release on October 28, 2026, the bilateral agreement positions the Canadian aerospace manufacturer to integrate its engineering and manufacturing footprint into allied military aviation requirements. The partnership aligns with Canada’s broader defense strategy, coming three months after the country formally engaged with international sixth-generation fighter development efforts.
Strategic framework and capability exploration
The MOU establishes an exploratory framework to identify practical areas of cooperation aligned with future capability requirements and government priorities. Rather than a commitment to a specific aircraft program, the agreement serves to connect Bombardier’s specialized supplier ecosystems with BAE Systems’ combat air expertise.
Stephen McCullough, Executive Vice President of Engineering, Product Development and Bombardier Defense, stated that the company is positioned to develop the talent required for programs carrying a generational impact on the defense industry.
“This MOU with BAE Systems provides a clear framework to explore how these capabilities can support next-generation defence programs, while strengthening industrial capacity, high-value jobs and long-term aerospace leadership,” McCullough said.
Simon Barnes, Group Managing Director of BAE Systems Air, noted the opportunity to support the strategic aims of Canada’s Defence Industrial Strategy through the collaboration.
“BAE Systems brings decades of combat air experience spanning aircraft design, systems integration, manufacturing and support. This agreement marks an important step in our ambition to strengthen international partnerships that support the future of combat air,” Barnes said.
Canada’s evolving role in next-generation air combat
The partnership materializes as Canada deepens its involvement in international air combat initiatives. On July 21, 2026, the Department of National Defence announced that Canada had joined the Global Combat Air Programme (GCAP) as its first observer nation.
GCAP is a multinational initiative led by the United Kingdom, Italy, and Japan to develop a sixth-generation fighter jet. Observer status allows the Canadian government to assess potential future participation and gain insight into the program’s governance and industrial framework. Crucially, the designation enables the identification of opportunities for domestic companies without requiring an immediate financial commitment from the state.
The bilateral agreement positions Bombardier to capture future procurement cycles as Canada evaluates its long-term role in next-generation air combat initiatives.
Industrial positioning and defense adaptation
Bombardier primarily designs, builds, and maintains the Global and Challenger families of business jets. The company reports a global operating fleet of over 5,300 aircraft, supported by 10 service facilities across six countries.
The manufacturer’s specialized division, Bombardier Defense, focuses on adapting these civilian airframes for military and government missions. The unit emphasizes reliability, performance, and adaptability for specialized operations. By partnering with BAE Systems, Bombardier seeks to expand its defense footprint beyond modified business jets and into the broader combat air supply chain.
BAE Systems operates as one of the primary industrial partners in GCAP, working alongside Italy’s Leonardo and Japan’s Mitsubishi Heavy Industries. The British aerospace and defense company brings extensive experience in systems integration and military aircraft manufacturing to the exploratory partnership with Bombardier.
AirPro News analysis
We view this MOU as a calculated positioning move by Bombardier to secure high-value engineering work within the lucrative sixth-generation fighter ecosystem. While Bombardier is not a traditional combat aircraft prime contractor, modern air combat programs rely heavily on distributed systems, advanced materials, and specialized sensor integration. By partnering with a Tier 1 prime like BAE Systems, Bombardier can leverage its existing aerospace engineering workforce and supply chain to capture defense revenue streams without the prohibitive cost of developing clean-sheet military airframes.
This industrial alignment also provides the Canadian government with tangible domestic economic benefits as it evaluates deeper participation in GCAP. Securing a role for a major domestic aerospace employer like Bombardier makes the political case for future Canadian financial investment in GCAP significantly stronger.
Photo Credit: BAE Systems
Defense & Military
AFRL and ACC Complete XQ-67A Autonomous Platform Flight Test
AFRL and ACC validate XQ-67A beyond-line-of-sight data links and mission systems at Nevada Test and Training Range.

The Air Force Research Laboratory (AFRL) and the Air Combat Command (ACC) Experimental Operations Unit successfully flew the XQ-67A Autonomous Collaborative Platform (ACP) at the Nevada Test and Training Range to validate integrated mission systems and beyond-line-of-sight data links.
Announced on October 27, 2026, the flight test demonstrated the ability of uncrewed systems to extend the operational reach of crewed fighter formations and provide deep situational awareness. The milestone advances the Department of the Air Force’s goal of adding affordable operational mass to the fleet while reducing risk to human aircrews.
Validating autonomous architectures
The recent flight was completed under the Demonstration of ACP Performance and Effectiveness (Demon APE) project. During the test, the XQ-67A demonstrated the integration of advanced mission systems, including sensors, mission computers, and power and thermal management hardware.
The integration of beyond-line-of-sight datalinks and live, virtual, and constructive simulations allowed operators to manage uncrewed platforms across distributed theaters. This capability is designed to support resilient command and control in dispersed combat operations.
Trenton White, an aerospace engineer with the Air Warfare Directorate at the AFRL, highlighted the technical achievements of the flight test.
“This proved that AFRL’s autonomous architectures, aligned with Autonomy and Agile Mission Suite Government Reference Architectures, can reliably process and relay combat-relevant data in real-world scenarios.”
The collaboration between research and operational units is intended to accelerate the deployment of new technologies. Col. Matthew Caspers, Deputy Technology Executive Officer for Air at the Department of the Air Force, emphasized the strategic value of the joint effort.
“By pairing AFRL’s rapid prototyping with ACC’s operational test units, the Air Force is shortening the timeline between concept and warfighter capability.”
The XQ-67A development path and OBSS origins
Designed and manufactured by General Atomics Aeronautical Systems, Inc. (GA-ASI), the XQ-67A was originally developed under the Off-Board Sensing Station (OBSS) program. It serves as the first of a second generation of Autonomous Collaborative Platforms.
The aircraft was built using a genus and species manufacturing concept. This approach utilizes a common core chassis, referred to as the genus, from which several distinct aircraft variants, or species, can be built. The shared architecture enables faster development cycles and lowers overall production costs.
The XQ-67A completed its maiden flight on February 28, 2024, at Gray Butte Field Airport in Palmdale, California. Following initial flight testing, the AFRL awarded GA-ASI a sole-source contract on January 17, 2025, for Demon APE Phase II. This contract funded the integration of specific mission systems and upgraded the vehicle to ensure adequate power generation and thermal management capacity for advanced payloads.
Expanding the Collaborative Combat Aircraft ecosystem
The XQ-67A builds on the foundational success of earlier uncrewed platforms, specifically the XQ-58A Valkyrie. The data and operational concepts validated by the XQ-67A complement ongoing efforts at the Air Force Test Center, including the X-62 VISTA and F-16 VENOM programs.
Together, these parallel testing tracks are designed to speed the fielding of Collaborative Combat Aircraft (CCA), a central component of the Department of the Air Force’s future force structure.
AirPro News analysis
The progression from the XQ-67A’s maiden flight in early 2024 to complex beyond-line-of-sight data link testing in late 2026 highlights the rapid maturation of the genus and species manufacturing model. By utilizing a common chassis to test modular mission systems, the AFRL is proving that the underlying architecture can support rapid iteration without requiring a clean-sheet aircraft design for every new sensor suite.
The successful demonstration of resilient command and control across distributed theaters is a critical prerequisite for the operational deployment of Collaborative Combat Aircraft. Proving that these platforms can reliably relay combat data beyond line of sight ensures they can operate effectively alongside crewed fighters in contested environments, validating the core premise of the CCA program.
Photo Credit: AFRL
Defense & Military
Saab Names Canadian Partners for Gripen E Fighter Bid
Saab AB names CAE, IMP Aerospace, and Magellan as partners for its Gripen E bid in Canada’s fighter replacement program.

Saab AB has outlined its proposed domestic supply chain for Canada’s future fighter acquisition program, naming CAE Inc., IMP Aerospace & Defence, and Magellan Aerospace as principal partners for the Gripen E bid.
In a press release issued on October 27, 2026, the Swedish aerospace manufacturer detailed a strategy to establish in-country final assembly, aerostructures manufacturing, and long-term sustainment. The industrial ecosystem is conditional on the Government of Canada selecting the Gripen E to modernize the Royal Canadian Air Force (RCAF) fleet.
Structuring the domestic supply chain
Saab has structured specific industrial agreements with the three Canadian entities to cover different phases of production and support. Under a Teaming Agreement, IMP Aerospace & Defence would establish a final assembly line, handle electrical assembly production, and provide in-service support (ISS) within Canada.
IMP Aerospace & Defence President David Gossen noted that the capability would meet domestic requirements while offering broader export potential.
“We see a real opportunity for IMP to produce and support aircraft for Gripen customers internationally, positioning Canadian industry as an enduring part of the global Gripen program,” Gossen said.
Saab signed a Memorandum of Understanding (MoU) with Magellan Aerospace for the local manufacturing of advanced aerostructures, composite structures, and structural assemblies. Magellan Aerospace Vice President of Business Development Haydn Martin stated the company is positioned to bring its manufacturing expertise to the program, supporting high-tech job creation and sovereign defense capabilities.
A separate MoU with CAE Inc. covers the delivery of advanced fighter pilot and technician training, mission systems engineering, and sustainment capabilities. CAE Defense & Security President Pascal Grenier highlighted the company’s longstanding commitment to RCAF training needs and its readiness to support Canada’s future fighter force.
Meeting Canada’s industrial requirements
The Canadian fighter replacement program requires bidders to offer significant domestic industrial and technological benefits. Saab’s proposed ecosystem aims to provide Canada with a self-reliant capability to deploy, sustain, and enhance the Gripen E aircraft over its operational life.
Saab AB President and CEO Micael Johansson described the potential acquisition as a long-term national investment.
“Together with CAE, IMP and Magellan Aerospace we are prepared to establish a strong Canadian industrial ecosystem around Gripen that delivers operational effect, national sovereignty and lasting industrial and technological benefits,” Johansson said.
The Gripen E and RCAF modernization
Saab designs and manufactures the Gripen series of advanced multi-role fighter aircraft alongside other defense and security systems. The company is offering the Gripen E to the Government of Canada as the replacement for the current RCAF fighter fleet. The activation of the partnerships with CAE, IMP Aerospace & Defence, and Magellan Aerospace remains entirely dependent on the government selecting the Swedish aircraft.
The three Canadian partners are established aerospace entities. CAE specializes in advanced simulation technologies and training services for defense forces globally. IMP Aerospace & Defence provides in-service support, engineering, and maintenance for military aircraft. Magellan Aerospace manufactures complex aerospace systems, aerostructures, and components.
AirPro News analysis
Saab’s industrial strategy highlights the stringent economic requirements embedded in Canada’s fighter replacement program. By offering a domestic final assembly line and integrating Canadian firms into the global supply chain, Saab is attempting to maximize its industrial and technological benefits proposition. The proposal for IMP Aerospace & Defence to potentially produce and support aircraft for international Gripen customers is particularly notable, as it offers long-term economic value that extends beyond the RCAF procurement cycle. We view this as a calculated move to address both sovereign defense capability and domestic economic priorities in a highly competitive acquisition process.
Photo Credit: Saab AB
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