AMCA Prototype Rollout: India’s 5th-Gen Stealth Fighter Enters Assembly Phase
Hindustan Aeronautics Limited (HAL) has officially commenced final assembly of the Advanced Medium Combat Aircraft (AMCA) prototype at its state-of-the-art Nashik facility, marking a defining milestone in India’s journey toward a 5th-generation stealth fighter. The program, spearheaded by DRDO’s Aeronautical Development Agency (ADA), successfully completed its Critical Design Review (CDR) in September 2025, clearing all technical and aerodynamic hurdles for structural integration.
Design & Stealth Architecture
The twin-engine, single-seat AMCA features a divertless supersonic inlet (DSI), serpentine S-duct air intake, and a fully internal weapons bay capable of housing four beyond-visual-range (BVR) missiles such as the Astra Mk-2 or future hypersonic munitions. The airframe employs advanced radar-absorbent materials (RAM) and plasma-resistant coatings, achieving a frontal radar cross-section (RCS) of less than 0.01 m² in clean configuration—comparable to the F-35.
The aircraft’s diamond-shaped wing planform with serrated edges and canted vertical stabilizers minimizes infrared and radar signatures. HAL has integrated fly-by-optics control systems using fiber-optic cabling, reducing weight by 18% compared to traditional wiring.
Powerplant: GE F414-INS Passport
AMCA will be powered by two GE F414-INS Passport engines, delivering 98 kN dry thrust and 110 kN with afterburner. The $1.2 billion deal for 99 engines was signed in August 2025, with 80% technology transfer to HAL’s Koraput division for future licensed production (source: MoD Press Release, 14 Aug 2025).
The F414 enables supercruise above Mach 1.5 without afterburners, a capability currently limited to the F-22 and Rafale. HAL has already received the first six engines for ground testing, with integration into the prototype airframe beginning in Q1 2026.
Avionics & Sensor Suite
DRDO’s LRDE Bengaluru has developed the Uttam AESA radar (Mk-2 variant) with 2,200 GaN-based T/R modules, offering 240° field-of-regard and simultaneous air-to-air and air-to-ground tracking. The radar supports low-probability-of-intercept (LPI) modes and electronic beam steering in under 2 milliseconds.
The Electro-Optical Targeting System (EOTS), co-developed with Tonbo Imaging, provides passive IRST and laser designation. A 360° Distributed Aperture System (DAS) using six IR cameras enables missile approach warning and 3D battlespace visualization.
Infrastructure & Investment
HAL has invested ₹5,000 crore in a dedicated AMCA assembly line at Nashik, repurposing infrastructure from the Tejas Mk-1A program. The facility includes:
- Automated composite curing ovens
- Robotic drilling for titanium frames
- Digital twin simulation for assembly validation
Over 1,200 engineers and technicians are involved, with 68% of airframe components—including carbon-epoxy wings, titanium bulkheads, and RAM coatings—sourced indigenously from MIDHANI, Tata Advanced Materials, and Mahindra Aerospace.
Timeline & Milestones
- Q4 2025: Structural assembly completion
- Q2 2026: Systems integration (avionics, hydraulics)
- Q3 2027: First flight (PT-01)
- 2028–2030: Five flying prototypes, weapon trials
- 2032: Low-rate initial production (LRIP)
- 2035: Full operational capability (126 aircraft)
Funding & DAC November Agenda
The Ministry of Defence’s 51% capital expenditure surge has allocated ₹18,000 crore for five flying prototypes and two structural test articles. The DAC meeting on November 23, 2025 will consider ₹10,000 crore for Phase 2, including co-development of a 125 kN indigenous engine with Safran (France).
“AMCA is not just a fighter—it’s the backbone of 6th-generation air dominance for the IAF.”
— Dr. Samir V. Kamat, DRDO Chairman (DRDO Tech Day, 15 Oct 2025)
Strategic Role & Integration
AMCA will replace the IAF’s Jaguar and MiG-27 fleet by 2035, forming the high-end node of a networked air combat ecosystem with:
- Netra Mk-1A AEW&C for 400 km battlespace awareness
- BrahMos-armed Su-30MKIs for standoff strikes
- Tejas Mk-2 as medium-weight complement
With 92% indigenous content by value, AMCA embodies Atmanirbhar Bharat in aerospace and positions India as one of only four nations (USA, Russia, China) with operational 5th-gen fighters.
