Aero India 2025: AMCA design undergoes further tweak due to additional testing

A full-scale model of India's AMCA aircraft displayed at Aero India 2025. (Janes/Akhil Kadidal )

India's fifth-generation Advanced Medium Combat Aircraft (AMCA) will undergo yet another critical design review (CDR), after enhanced stress/load testing determined that the design required additional tweaks, according to a project official.

Speaking to Janes during Aero India 2025, held from 10 to 14 February, the project official – a member of the Aeronautical Development Agency (ADA) – specified that initial stress/load tests were conducted with 90% of the projected load, as per the agency's methodology.

However, the official added that the agency management has since issued instructions to ensure that the airframe and structure of the planned aircraft is capable of supporting 100% of the required loads.

Janes understands that the stress/load testing is being conducted using the finite element method (FEM), a numerical technique used to solve complex differential equations in engineering and science by dividing a problem domain into smaller, simpler finite elements. As the AMCA is due to incorporate additional design changes to accommodate the latest findings, a CDR is required to freeze the design of the aircraft, the official said. ADA plans to complete the review in April 2025, the official added.

Metal-cutting activities will be conducted later in 2025, Janes understands. Programme officials had intended to start metal-cutting activities in 2024, following the Indian government's Cabinet Committee on Security (CCS) approval of the project in March 2024. The CCS approval allowed funding of up to INR150 trillion (USD1.7 billion) to be disbursed to the programme.