Analysis How India's Aerospace Giants Forge Critical Engine Parts yet Remain Distant from Achieving True Self-Reliance

How India's Aerospace Giants Forge Critical Engine Parts yet Remain Distant from Achieving True Self-Reliance


Prominent headlines have recently celebrated the entry of Indian manufacturing firms into the high-stakes arena of global commercial aviation.

With Godrej Aerospace securing agreements with Pratt & Whitney for turbine components and Azad Engineering manufacturing essential parts for Rolls-Royce jet engines, the prevailing narrative suggests India is on the verge of becoming an aerospace superpower.

These manufacturers are now producing sophisticated components that power the massive aircraft of Boeing and Airbus worldwide.

While these offset agreements and supply chain inclusions undoubtedly generate employment, train machinists in advanced skills, and infuse over ₹10,000 crore annually into the local economy, they tell only part of the story.

However, looking beyond the impressive announcements reveals a more complex reality: these achievements do not necessarily equate to technological sovereignty.

Instead, they often represent highly restricted subcontracts where Original Equipment Manufacturers (OEMs) such as GE, Rolls-Royce, and Pratt & Whitney maintain absolute control. These global giants dictate every aspect of production, from the raw metal ingots used to the specific calibration of tools.

This strict oversight effectively stifles local innovation and prohibits reverse engineering, ensuring that Indian firms remain efficient manufacturers rather than becoming independent design powerhouses.

In a sector where a single engine design, such as the GE9X or Trent XWB, represents billions of dollars in intellectual property (IP), these partnerships are frequently portrayed as mutual technological growth.

However, for India’s vision of Atmanirbhar Bharat, they present a paradox: they bring significant economic activity but offer little in the way of deep technological transfer.

The industry operates on a "build-to-print" model, where local companies add value through labour and precision rather than through the creation of new intellectual property.

It is easy to be captivated by the excitement surrounding these developments.

For instance, when Hyderabad-based Azad Engineering Ltd. announced its contract in February 2025 to manufacture critical engine parts—specifically high-precision rotors and casings for the Pearl 15 engine—for Rolls-Royce, its stock value rose by 15%. Industry observers quickly labelled it a milestone for Indian manufacturing.

Similarly, a July agreement between Godrej Aerospace and Pratt & Whitney (a division of RTX) to produce complex structural components at its Mumbai facility is set to create 500 jobs and build expertise in specialised fields like CNC machining and heat treatment.

These are not isolated events; following supply chain disruptions in the West, major OEMs including Airbus and Collins Aerospace have directed approximately $2 billion in orders to Indian suppliers since 2023.

The tangible benefits of these collaborations are undeniable. India is cultivating a workforce capable of working with aerospace-grade tolerances, where accuracy is measured in microns.

This has also spurred growth in ancillary sectors, such as the production of heat-resistant alloys by Mishra Dhatu Nigam, contributing to India’s $2.6 billion defence and aerospace export figures.

For companies like Tata Advanced Systems or Dynamatic Technologies—which manufacture fan blades for GE—this represents a vital entry into the $100 billion global engine market.

Yet, unlike the government-to-government deal for the GE F-414 engine which promises some technology transfer to Hindustan Aeronautics Limited (HAL), these private sector deals are strictly precision subcontracts. Indian companies execute existing blueprints; they do not create them.

Global OEMs are protective of their proprietary technologies, which are worth trillions of dollars. Contracts are heavily guarded by non-disclosure agreements and IP restrictions that forbid any deviation from the plan. Improving a blade's angle for better efficiency or attempting to adapt a composite fan for local use is legally impossible.

As an engineer from a Tier-2 supplier in Bengaluru noted, their role is confined to following the provided CAD files and verifying materials using the OEM’s equipment, with innovation limited strictly to speeding up the production process.

This dependency extends to the very beginning of the supply chain. Essential raw materials, such as titanium sponge imported from Russia or superalloys from Special Metals, often arrive pre-certified to avoid any risk of contamination.

Even the manufacturing tools—specialised jigs and fixtures—are frequently proprietary and leased under strict audits to prevent unauthorised replication.

Quality control is equally centralised; experts from companies like Pratt & Whitney are often stationed on-site for inspections, while Rolls-Royce’s supplier programmes demand absolute perfection, with the threat of contract termination for quality failures.

Such caution is driven by safety rather than paranoia, in an industry where counterfeit parts can have catastrophic consequences. A 2024 Federal Aviation Administration (FAA) investigation into unapproved parts highlighted that even a single defective blade could endanger a flight.

For India, the result is a manufacturing sector that is highly skilled at execution but starved of research and development (R&D) opportunities. This gap is evident in the struggles of the indigenous Kaveri engine programme. Despite decades of effort and over ₹2,000 crore in investment, the engine has not yet powered a fighter jet.

However, open-source developments indicate a pivot: the "Dry Kaveri" variant is now being adapted to power the stealthy Ghatak Unmanned Combat Aerial Vehicle (UCAV), suggesting a shift towards achievable milestones rather than immediate manned flight.

The illusion of rapid progress persists because it is commercially and politically attractive. The government highlights global integration, and companies celebrate their rising stock prices.

Yet, without achieving technological sovereignty, this success remains fragile. If global OEMs shift to new technologies—such as 3D-printed blades or hydrogen propulsion—Indian manufacturing lines, without the ability to design their own solutions, risk becoming obsolete overnight.
 
Real Indian start ups will arrive sooner or later and show these dinosaurs how to lose weight and become lizards.
 
This article is stating the obvious but avoids analyzing the ramifications. When you win a contract to deliver windows for my new house I will obviously give you the size, material specifications and all other details. I'm not going to be very thrilled if you change my wooden frame window to an aluminium frame etc. I am not paying you to R&D on my requirement. I have not engaged you for consultancy work. There's nothing new in this. That's how all contracts work... Have always worked so.

What the author failed to understand is the deeper ramifications of such experience and expertise that the skilled workforce is picking up. It is not just the machinist who is operating a complex CNC machine and learning to work at very low tolerance levels. There are also smart supervisors and floor engineers who are absorbing these details, the material getting used, the design files shared by the company etc. And this where eventually the seeds of new ideas germinate. When a godrej strongly pitches for the inhouse development of the AMCA engine it is not because DRDO allowed them to do a lot of R&D on their KDE variant that godrej was subcontracted to build. But it's godrej's years of experience working with ISRO with low tolerance designs, materials for space grade engines, their experience in building for other aerospace majors and then having seen the KDE, seen what it produces when fired, and limitations it works within. They possibly feel that they know a thing or two that can be tried out, or things that should be avoided etc. based on their experiences of having worked on various such projects.

That's the net gain. Also the fact that no one gets to enter directly at the top of the value chain is a key thing. Only when an Indian firm has accumulated certain years of experience doing a specific type of work will possibly when they will qualify to bid for a high value component design the next time around for a global major. But then doing all the reasearch with supporting data will need some effort. Much easier to rehash the known and say we are just doing the labour work.
 
India can easily build the best 4th gen engine in the world. We just lack the testing facilities, due to which each prototype has to be tested in Russia which makes it virtually impossible since it delays testing by 2-3 years. Don't blame Russia, they have to test their own engines first. Blame our govts who have NOT funded these testing facilities despite DRDO begging them to do so for decades. Blame strictly lies on both the current & the former govts.
 
This article is stating the obvious but avoids analyzing the ramifications. When you win a contract to deliver windows for my new house I will obviously give you the size, material specifications and all other details. I'm not going to be very thrilled if you change my wooden frame window to an aluminium frame etc. I am not paying you to R&D on my requirement. I have not engaged you for consultancy work. There's nothing new in this. That's how all contracts work... Have always worked so.

What the author failed to understand is the deeper ramifications of such experience and expertise that the skilled workforce is picking up. It is not just the machinist who is operating a complex CNC machine and learning to work at very low tolerance levels. There are also smart supervisors and floor engineers who are absorbing these details, the material getting used, the design files shared by the company etc. And this where eventually the seeds of new ideas germinate. When a godrej strongly pitches for the inhouse development of the AMCA engine it is not because DRDO allowed them to do a lot of R&D on their KDE variant that godrej was subcontracted to build. But it's godrej's years of experience working with ISRO with low tolerance designs, materials for space grade engines, their experience in building for other aerospace majors and then having seen the KDE, seen what it produces when fired, and limitations it works within. They possibly feel that they know a thing or two that can be tried out, or things that should be avoided etc. based on their experiences of having worked on various such projects.

That's the net gain. Also the fact that no one gets to enter directly at the top of the value chain is a key thing. Only when an Indian firm has accumulated certain years of experience doing a specific type of work will possibly when they will qualify to bid for a high value component design the next time around for a global major. But then doing all the reasearch with supporting data will need some effort. Much easier to rehash the known and say we are just doing the labour work.
That being said, it's remarkable that the Su-57 process has been completed and our wooden windows evaluated and proposals for aluminium frames presented at an international Air Show.
 
To get started in such high tech, high quality safety parts, we need discipline and tested work process.
To gain this expertise we need to follow protocols established by these experienced firms. The fact that they are willing to source due to local content or otherwise is indeed a first baby step towards greater things. Rome is not built in a day.
 
This article is stating the obvious but avoids analyzing the ramifications. When you win a contract to deliver windows for my new house I will obviously give you the size, material specifications and all other details. I'm not going to be very thrilled if you change my wooden frame window to an aluminium frame etc. I am not paying you to R&D on my requirement. I have not engaged you for consultancy work. There's nothing new in this. That's how all contracts work... Have always worked so.

What the author failed to understand is the deeper ramifications of such experience and expertise that the skilled workforce is picking up. It is not just the machinist who is operating a complex CNC machine and learning to work at very low tolerance levels. There are also smart supervisors and floor engineers who are absorbing these details, the material getting used, the design files shared by the company etc. And this where eventually the seeds of new ideas germinate. When a godrej strongly pitches for the inhouse development of the AMCA engine it is not because DRDO allowed them to do a lot of R&D on their KDE variant that godrej was subcontracted to build. But it's godrej's years of experience working with ISRO with low tolerance designs, materials for space grade engines, their experience in building for other aerospace majors and then having seen the KDE, seen what it produces when fired, and limitations it works within. They possibly feel that they know a thing or two that can be tried out, or things that should be avoided etc. based on their experiences of having worked on various such projects.

That's the net gain. Also the fact that no one gets to enter directly at the top of the value chain is a key thing. Only when an Indian firm has accumulated certain years of experience doing a specific type of work will possibly when they will qualify to bid for a high value component design the next time around for a global major. But then doing all the reasearch with supporting data will need some effort. Much easier to rehash the known and say we are just doing the labour work.
I feel the correct in his way of expressions, views & ideas......

We sould have started our material science technology earlier, i.e. in the area's of Single Crystal blade, super alloys, thermal barrier coatings etc.... cooling techniques for the turbine blades etc...... cobalt based super alloys etc.....

If we don't develope it, we have to purchase it..... High cost consumption......

MIDHANi is slowly succeeding the area of special alloys & super alloys.... Still a long way to go.....

One contractor might be giving Window and another might be expert in the restroom firmware including washbasin and the toilet utensils.....

Who will look into the structure of the building, who plans the safety precautions, who looks into terrace moulding with water proof materials......

So the author gives us exact picture.... We need to go a long still at this circumstance.....

A good article..... Private partners too struggle hard to their level as they are not exposed to the entire technology.......
 
It's a complex phenomenon. The big giants have sunk to become redundant & young dynamic startup with open arms and minds have become more responsible in delivering the results.
 
It's a complex phenomenon. The big giants have sunk to become redundant & young dynamic startup with open arms and minds have become more responsible in delivering the results.
Looking at our youngsters I feel that these are our best products. Their grandparents and parents have looked after their needs superbly and they are open and flexible enough to look through things in different ways. They need to be Massively recruited and trained. That's where our money needs to be spent. Social security forces need to assist any begging individuals and arrange suitable employment support and their children recruited and paid to study. It may be that they work as fully paid under-aged assistants. Human resources are our strengths. Let's train them.
 
This article is stating the obvious but avoids analyzing the ramifications. When you win a contract to deliver windows for my new house I will obviously give you the size, material specifications and all other details. I'm not going to be very thrilled if you change my wooden frame window to an aluminium frame etc. I am not paying you to R&D on my requirement. I have not engaged you for consultancy work. There's nothing new in this. That's how all contracts work... Have always worked so.

What the author failed to understand is the deeper ramifications of such experience and expertise that the skilled workforce is picking up. It is not just the machinist who is operating a complex CNC machine and learning to work at very low tolerance levels. There are also smart supervisors and floor engineers who are absorbing these details, the material getting used, the design files shared by the company etc. And this where eventually the seeds of new ideas germinate. When a godrej strongly pitches for the inhouse development of the AMCA engine it is not because DRDO allowed them to do a lot of R&D on their KDE variant that godrej was subcontracted to build. But it's godrej's years of experience working with ISRO with low tolerance designs, materials for space grade engines, their experience in building for other aerospace majors and then having seen the KDE, seen what it produces when fired, and limitations it works within. They possibly feel that they know a thing or two that can be tried out, or things that should be avoided etc. based on their experiences of having worked on various such projects.

That's the net gain. Also the fact that no one gets to enter directly at the top of the value chain is a key thing. Only when an Indian firm has accumulated certain years of experience doing a specific type of work will possibly when they will qualify to bid for a high value component design the next time around for a global major. But then doing all the reasearch with supporting data will need some effort. Much easier to rehash the known and say we are just doing the labour work.
Very good analysis. This how China leap frogged ahead of us. It is not wise to teamnul with western companies in defence tech. They are way behind Russia and China evc India if one were to consider hypersonic missiles. Noné in the west has it. Two examples. Around a year ago UK navy tried to test fire a nuclear capable missile. It just dropped next to launching submarine. Next an F35 made an emergency landing in Kerala , India. It took all the techies n engineers with a plane load of equipment 35 days to her flying. Why would we need such obsolete technology? Jai Hind
 
I've been opining the same thing again and again in a few portals including this one and let me state it one more time.

You want to be the design powerhouse rather than just being the best manufacturers who are dictated by the Western design powerhouses and take orders from them ?

Bring in the best and the brightest of our elite technological schools such as IITs, IISc etc and work with them hand in gloves.

You're talking about Pratt and Whitney. They didn't become the design powerhouse by struggling and stammering themselves alone. They worked with MIT for their engine project and completed it in just 10 years

They didn't have the dearth of expertise. In fact a couple of my neighbors who work there are IIT-ans. But that didn't stop them from bringing in additional best from the top school.

That's the most valuable, most needed, most crucial missing link in India.

IT'S HIGH TIME INDIA DOES THAT.
 

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