The Indian government has authorized the production of a specialized assembly jig, a critical tool for integrating a retractable in-flight refueling probe into the Tejas Mk2 fighter jet, also known as the Medium Weight Fighter (MWF).
This decision, announced in February 2025, marks a significant advancement in the development of India's indigenous Light Combat Aircraft (LCA) program.
The assembly jig is a precision instrument used in aircraft manufacturing to accurately align and assemble complex components. In this case, it will be specifically designed for the integration of the retractable Air-to-Air Refueling (AAR) probe module into the front fuselage of the LCA Mk2.
The Aeronautical Development Agency (ADA) has initiated the procurement process, partnering with Hindustan Aeronautics Limited's (HAL) Aircraft Research and Design Centre (ARDC) to develop this crucial piece of equipment.
Unlike the fixed refueling probes found on earlier Tejas models, which were supplied by Cobham, the Mk2 will utilize a retractable telescopic probe employing a Probe and Drogue system. This design minimizes aerodynamic drag when the probe is not in use, leading to improved fuel efficiency and reduced radar signature, enhancing the aircraft's stealth capabilities.
The design and production of the jig will utilize advanced design software, CATIA 5, the same software used that is used for the Mk2's airframe. This will ensure a smooth and efficient integration with the aircraft's modular construction.
This modular approach, a departure from the serial assembly of the Mk1, was showcased during Air Marshal R.K.S. Rajkumar's visit to HAL's design facilities in January 2025.
Once installed, the retractable probe will allow the Mk2 to receive fuel mid-air from Indian Air Force (IAF) tankers, such as the IL-78, significantly extending the aircraft's operational range. Currently, the combat radius of similar aircraft is approximately 500-600 km; in-flight refueling can potentially double the Mk2's mission endurance to over 120 minutes.
This approval is part of the larger ₹10,000 crore (approximately $1.2 billion USD) LCA Mk2 project, sanctioned in 2022. The project aims for the Mk2's first flight by late 2025 or early 2026, with operational induction into the IAF planned for 2028.
The retractable AAR probe is one of many upgrades, including an indigenous Uttam Active Electronically Scanned Array (AESA) radar, increased indigenous components (targeting 82% initially), and a smaller frontal Radar Cross Section (RCS).
These enhancements position the Mk2 as a 4.5-generation fighter with aspirations to reach 5.5-generation capabilities. The IAF plans to acquire six squadrons of the Mk2, demonstrating its confidence in the aircraft's multirole capabilities.
The government's proactive approval of the jig's development, with 55% of the first prototype reportedly complete as of Aero India 2025, addresses past delays experienced in the Mk1 program related to testing and integration. This ensures that HAL can expedite the assembly process once the GE F414 engines, expected to arrive in late 2025, are delivered.
The enhanced range provided by in-flight refueling gives the Mk2 a significant tactical advantage in potential conflicts. It allows for sustained operations over contested areas, such as Ladakh or the Line of Control (LoC), providing a capability that can challenge adversaries. The combination of agility and extended endurance, particularly in high-altitude environments where refueling logistics are complex, makes the Mk2 a potent asset for the IAF.
