Tejas Mk2 Production on Fast-Track with Digital Manufacturing and Laser-Guided Precision, Solidifying Early 2026 Rollout Plans

The development of India's next-generation fighter jet, the Tejas Mk2, is advancing at a rapid pace, with Hindustan Aeronautics Limited (HAL) leveraging cutting-edge digital manufacturing techniques to meet its ambitious timelines.

The state-owned aerospace and defence company confirmed that key components are already being produced, positioning the first prototype for a scheduled rollout in early 2026.

According to HAL's Chairman and Managing Director, DK Sunil, the project has moved into a critical phase of construction. "Parts are being manufactured, and we are now into sub-assemblies, with production of the wings and fuselage going on," he stated in a recent interview.

HAL has set a firm target to unveil the first aircraft between January and March of 2026.

Following the rollout, the aircraft will undergo initial power-on and extensive ground checks, with its crucial maiden flight anticipated later the same year.

A significant factor accelerating the production schedule is HAL's adoption of advanced digital technology. Unlike previous aircraft developed using traditional physical drawings, the Tejas Mk2 is being built from the ground up using precise 3D digital models. This "digital thread" approach allows for greater accuracy in manufacturing.

After components are fabricated, they are meticulously checked with laser scanners to ensure they conform perfectly to the digital blueprint, a process that enhances both the speed and precision of the assembly.

While these digital manufacturing methods mark a major leap forward, DK Sunil noted that a complete "digital twin"—a virtual replica of the aircraft for real-time simulation and testing—is a future goal currently in development.

HAL is establishing a dedicated data cloud to support this capability, which will further streamline testing and maintenance throughout the aircraft's lifecycle.

The Tejas Mk2 is being developed as a 4.5-generation Medium Weight Fighter, representing a substantial upgrade over the existing Tejas Mk1 and the upcoming Mk1A variants.

Officially sanctioned for development by the Cabinet Committee on Security (CCS), the Mk2 is designed with superior capabilities, including a higher payload capacity of 6,500 kg, an extended range, and 11 hardpoints for mounting weapons and sensors.

It will be powered by a single, more powerful General Electric F414-INS6 engine, which has already been contracted for supply.

The Indian Air Force (IAF) plans for the Tejas Mk2 to be a cornerstone of its future fleet, eventually replacing its ageing squadrons of Jaguar and Mirage 2000 jets in the 2035-2040 timeframe.

HAL anticipates a substantial order from the Indian government for at least eight squadrons, which would translate to between 100 and 130 aircraft.

While a formal order from the IAF is yet to be placed, the progress of the Tejas Mk2 programme is seen as a major boost for India’s goal of self-reliance, encapsulated in the 'Make in India' initiative.

The successful development and induction of this advanced indigenous fighter will significantly reduce the nation's dependence on foreign military hardware and cement HAL's position as a capable producer of world-class combat aircraft.

 

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[king dorm]

We have not even signed the deal for F-414 engines. How are we expecting to roll out Mk2 by next year? 🤔🤔🤔

 

[sanket]

We have not even signed the deal for F-414 engines. How are we expecting to roll out Mk2 by next year? 🤔🤔🤔

For prototype of Tejas MK2 four GE-414 Engine have been already delivered.

 

[SURESH RAO]

For prototype of Tejas MK2 four GE-414 Engine have been already delivered.

Not four. But 8 GE 414 engines have been delivered for Tejas MK2 prototypes development

For MK1 prototype development, 15 GE 404 engines were delivered from 2001 to 2010. And 40 GE 404 engines were delivered for MK1 serial production. Some more GE 404 engines were delivered for Naval LCA prototypes during 2010 to 2017.

 

[Sandeep]

It’s great if they can actually develop the jet on time but they will need to manufacture a lot more jets to increase our squadron strength. India should look at manufacturing around 200 of these jets which will be much cheaper than the MRFA competition and making foreign expensive imports all of the time. We can also use stealth paint to make it very difficult to detect the jets to increase its survival rate.

In a war you don’t need to use stealth jets all of the time as once you achieve air superiority with no SAM, radars or have just a few jets left as a threat then you can do without using your own stealth jet and bomb away. It’s also much cheaper to use 4.5th generation jets than stealth jets in the long term because of the amount of maintenance that’s required.

 

[jason smith]

The only area India is doing somewhat better in is missiles, radar tech, and shipbuilding. Every other project is in shambles, especially in the aeronautical department. Almost three decades since the initialization of the Kaveri program, and we have no engine at the moment.

However, we excel in "falani behen yojna" and "dhimka beti yojna," etc., "samman yojna." I've been following economic and military developments since 2010, and sad to say, we are going nowhere.

Smart and wise people work hard, gain enough wealth, send their kids to study abroad, and when they get PR, they themselves leave the country, taking all their wealth along with them. Sigh!

 

[Dranzer Knight]

They just keep lying and giving timelines I mean previously they said the rollout would be between October to December 2025 and now it has been shifted to January to March 2025 as usual incompetent HAL🤣🤣🤣