MRO & Manufacturing
Sikorsky Restarts Production of S-92A+ Heavy-Lift Helicopter
Sikorsky resumes production of the upgraded S-92A+ helicopter with enhanced safety features and new manufacturing strategy.
This article is based on an official press release from Lockheed Martin and additional industry data.
Sikorsky, a Lockheed Martin company, has officially commenced the production ramp-up of the S-92A+, the newest iteration of its heavy-lift helicopters. Announced on March 6, 2026, this move marks a significant restart for the S-92 program, driven by renewed global demand in the offshore energy and VIP transport sectors. The manufacturers has confirmed an initial production batch of five aircraft, with the first deliveries anticipated in 2028.
According to the company’s announcement, the decision to restart production follows the complete absorption of surplus S-92 inventory that accumulated during the 2020 market downturn. With the existing fleet now fully utilized, Sikorsky is pivoting to a new manufacturing strategy that splits operations between Connecticut and New York to meet future capacity needs.
Sikorsky has established a production capacity of up to 12 aircraft annually. The initial build cycle involves five helicopters: two have already been ordered by an undisclosed 14th country for Head of State transport, while the remaining three are being built on speculation (“spec”) to meet anticipated near-term market requirements.
The manufacturing process involves a strategic division of labor across Sikorsky’s facilities:
Due to the complex supply chain and manufacturing requirements, the production lead time is estimated at 24 to 36 months, placing the first customer deliveries in 2028.
The S-92A+ helicopter is another example of how we are modernizing the fleet and transforming for the future, and we are building in surge capacity to meet expected demand.
, Rich Benton, VP and General Manager at Sikorsky
Sikorsky has standardized all future production on the S-92A+ configuration. This variant integrates several performance and safety upgrades that distinguish it from legacy models. The previously discussed “S-92B” designation appears to have been consolidated into this new A+ standard.
The most critical upgrade in the S-92A+ is the Phase IV main gearbox. This component replaces the previous magnesium housing with aluminum to enhance durability and repairability. More importantly, it features a new auxiliary lubrication system designed to address historical safety concerns. According to technical details released by the manufacturer, this system allows the gearbox to continue operating safely for a certified period even after a complete loss of primary oil pressure. Sikorsky executives have stated that the gearbox has a minimum operating lifecycle of over 6,000 flight hours.
In addition to the gearbox, the S-92A+ features upgraded General Electric CT7-8A6 engines. These powerplants are optimized for “hot and high” environments, providing better performance at high altitudes and temperatures. The aircraft also boasts a gross weight expansion to 27,700 lbs, which allows operators to carry an additional 1,200 lbs of payload or fuel compared to previous baselines.
The S-92 remains the aircraft of choice for Head of State, offshore energy and search and rescue operators who want the highest available flight-time helicopter… We haven’t had any damage to the [Phase IV] gearbox… and we’ve put it through some things that we weren’t planning to.
, Leon Silva, VP of Global Commercial & Military Systems
The introduction of the Phase IV gearbox is a significant development for the S-92 program, directly addressing the “run dry” capability that has been a focal point for aviation safety regulators. The S-92’s lubrication system came under intense scrutiny following the 2009 crash of Cougar Helicopters Flight 91 off the coast of Newfoundland. In that incident, a loss of gearbox oil pressure led to a catastrophic failure before the pilots could land.
By investing over $100 million in the development of the Phase IV gearbox, Sikorsky is closing the loop on this vulnerability. The new auxiliary lubrication system is designed to ensure that if primary oil is lost, the backup engages immediately, keeping the gears lubricated long enough to execute a safe landing. This upgrade is not merely a performance booster; it is a critical safety redundancy that aligns the airframe with the most stringent modern certification standards.
When will the new S-92A+ helicopters be delivered? What is the difference between the S-92A+ and older models? Where are the new helicopters being built? Why is Sikorsky restarting production now? Sources: Lockheed Martin, FlightGlobal, Vertical Magazine, RotorHub International
Sikorsky Restarts Heavy-Lift Production with New S-92A+ Variant
Production Strategy and Timeline
Technical Specifications: The S-92A+ Standard
Phase IV Main Gearbox
Performance Enhancements
AirPro News Analysis: The Safety Context
Frequently Asked Questions
First deliveries are expected around 2028, due to a 24–36 month production lead time.
The S-92A+ includes the Phase IV main gearbox with an auxiliary lubrication system, upgraded GE CT7-8A6 engines, and a gross weight increase to 27,700 lbs.
Dynamic components are manufactured in Stratford, Connecticut, while final assembly has moved to Owego, New York.
The company states that the surplus inventory of used S-92s has been fully absorbed by the market, creating a need for new airframes to support VIP transport and offshore energy sectors.
Photo Credit: Sikorsky