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The Aeronautical Development Agency (ADA) has taken a significant step forward in the development of India’s fifth-generation fighter jet, the Advanced Medium Combat Aircraft (AMCA).
The agency has released a comprehensive Statement of Work (SOW) inviting vendors to manufacture a test section of a bulkhead frame. This move is aimed at validating the complex manufacturing and inspection processes required for the stealth aircraft's primary structure.
Validation of Indigenous Manufacturing
The primary objective of this new mandate is to produce a single test article of a bulkhead frame. Bulkheads are critical vertical partitions within an aircraft's fuselage that provide structural integrity, support heavy loads, and help maintain the aircraft's shape under high stress.For the AMCA, this component is described as a highly complex, load-bearing structure featuring intricate pockets, ribs, and curved load paths.
The successful production of this test section will demonstrate the capability of Indian industry to handle the tight tolerances and sophisticated geometry required for modern stealth fighters, where weight optimisation and structural strength are paramount.
Advanced Materials and Digital Design
According to the SOW, the component will be machined from an aluminium-lithium alloy plate, a raw material that ADA will supply directly to the selected vendor.Aluminium-lithium alloys are increasingly preferred in modern aerospace engineering over traditional aluminium because they offer a superior strength-to-weight ratio and better resistance to fatigue—crucial factors for a high-performance combat aircraft.
A key highlight of this project is the adoption of Model Based Definition (MBD). In a departure from traditional reliance on 2D paper drawings, the manufacturing data will be shared exclusively through digital 3D formats (such as STP files and 3D PDFs).
This approach aligns the AMCA programme with global aerospace standards, reducing ambiguity between the design team and the manufacturer. However, it also places a higher responsibility on vendors to accurately interpret digital datasets for precision CNC (Computer Numerical Control) machining.
Strict Quality and Security Protocols
The manufacturing process outlined is rigorous. The selected vendor must design their own custom holding fixtures to machine the part strictly according to the provided CAD models.Following the machining process, the component will undergo thorough deburring and a comprehensive dimensional verification.
Quality assurance will be conducted using Coordinate Measuring Machine (CMM) inspection. This process will be carried out at the vendor's facility but must be witnessed by ADA personnel to ensure complete transparency and process discipline. A detailed CMM report must accompany the delivery of the finished part.
Given the sensitive nature of the AMCA’s design, strict intellectual property controls are in place. Vendors are required to sign a non-disclosure agreement (NDA), and the digital designs remain the confidential property of ADA, permissible for use only for this specific task.
Strategic Context
This development follows the Cabinet Committee on Security’s (CCS) approval of the AMCA development project in March 2024, with an estimated budget of ₹15,000 crore.The AMCA is envisioned as a stealthy, multi-role fighter intended to replace the Indian Air Force's ageing fleets and complement the LCA Tejas.
By validating the manufacturing protocols for critical components like the bulkhead now, ADA is laying the groundwork to ensure smooth production when the full-scale prototyping phase begins. The first flight of the AMCA is currently targeted for approximately 2028-29.
