The Aeronautical Development Agency (ADA) has taken a major step forward in India’s ambitious fifth-generation fighter program, the Advanced Medium Combat Aircraft (AMCA), by initiating a key industrial validation process. The agency has released a comprehensive Statement of Work (SOW) inviting vendors to manufacture a test section of a bulkhead frame, a move aimed at validating complex manufacturing and inspection processes essential for the stealth fighter’s primary structure.
The bulkhead, a critical vertical partition within the aircraft’s fuselage, plays a pivotal role in maintaining structural integrity, supporting heavy loads, and preserving the aircraft’s shape under high-stress conditions. For the AMCA, the component is described as a highly complex, load-bearing structure featuring intricate pockets, ribs, and curved load paths. Successfully producing this test section will demonstrate the capability of Indian industry to handle the tight tolerances and sophisticated geometry required for modern stealth aircraft, where weight optimization and structural strength are critical.
According to the SOW, the test component will be machined from an aluminium-lithium alloy plate, supplied directly by ADA to the selected vendor. Aluminium-lithium alloys are increasingly favored in modern aerospace engineering over traditional aluminium because they offer superior strength-to-weight ratios and better resistance to fatigue—factors essential for a high-performance combat aircraft.
A notable innovation in this project is the adoption of Model Based Definition (MBD). Departing from traditional 2D paper drawings, the manufacturing data will be shared exclusively through digital 3D formats, including STP files and 3D PDFs. This approach aligns the AMCA program with global aerospace standards, minimizing ambiguity between the design team and manufacturers. However, it also places greater responsibility on vendors to interpret digital datasets accurately for precision CNC (Computer Numerical Control) machining.
The manufacturing process outlined in the SOW is rigorous. Vendors must design custom holding fixtures to machine the bulkhead precisely according to CAD models. After machining, the component will undergo meticulous deburring and a thorough dimensional verification process. Quality assurance will be conducted using Coordinate Measuring Machine (CMM) inspection at the vendor’s facility, with ADA personnel witnessing the process to ensure full transparency. A detailed CMM report will be required with the finished part.
Given the sensitive nature of the AMCA’s design, strict intellectual property protocols are in place. Vendors are required to sign non-disclosure agreements, and digital designs remain the confidential property of ADA, permitted for use solely for this task.
This development follows the Cabinet Committee on Security’s (CCS) approval of the AMCA program in March 2024, which carries an estimated budget of ₹15,000 crore. The AMCA is envisioned as a stealthy, multi-role fighter designed to replace India’s ageing fleets and complement the indigenous LCA Tejas.
By validating the manufacturing protocols for critical components like the bulkhead at this stage, ADA is laying the groundwork for smoother production during the full-scale prototyping phase. Industry experts note that mastering such complex, high-precision structures is essential for keeping the AMCA program on track. The aircraft’s first flight is currently targeted for 2028-29, and developments like this underscore India’s commitment to indigenous fifth-generation fighter capabilities.
With this initiative, ADA not only tests industrial readiness but also signals India’s growing prowess in high-technology aerospace manufacturing, marking a significant milestone in the country’s journey toward producing homegrown stealth fighters.
