The UK is starting production of a fighter aircraft, the precursor to the Tempest fighter, incorporating cutting-edge technologies for 2035.

The UK recently launched production of its first manned combat aircraft demonstrator in 40 years, in collaboration with industrial giants such as BAE Systems and Rolls-Royce. The demonstrator will be used to test advanced technologies, such as stealth and next-generation avionics systems, as part of the development of the Tempest fighter, planned for 2035. The project incorporates innovative manufacturing methods, including 3D printing, to speed up production and reduce costs. The demonstrator’s maiden flight is scheduled for between 2026 and 2027.

Production launch: a strategic project for the UK

The start of production of the combat aircraft demonstrator by the United Kingdom marks a decisive turning point in the history of its aeronautics industry. This project, the first of its kind in four decades, is being led by a consortium of companies including BAE Systems, Rolls-Royce and MBDA UK, in close collaboration with the UK Ministry of Defence. The initiative reflects the UK government’s strategic commitment to strengthening its defence capabilities, particularly in the face of emerging threats.

The Tempest, which is at the heart of this initiative, represents a significant advance in modular and autonomous combat aircraft. Scheduled to be operational by 2035, the Tempest will be designed to incorporate cutting-edge technologies such as artificial intelligence (AI), directed energy weapons and the ability to control swarm drones. These elements are essential to meet future military requirements, where speed of decision and precision will be crucial.

The demonstrator, which is currently in production, will be used to test these technologies in real-life conditions, before they are integrated into the final model. This approach not only validates theoretical concepts, but also optimises development costs and timescales. For example, using 3D printing and Hot Isostatic Pressing (HIP) to produce metal parts minimises waste and speeds up the production chain.

Integrated technologies: an innovation-driven approach

The integration of technologies into the Tempest demonstrator is a crucial aspect of the project. Among these, stealth and new-generation avionics systems are at the heart of the project. Stealth, or an aircraft’s ability to avoid radar detection, has become a major issue in the development of modern combat aircraft. It is based on materials that absorb radar waves, and on shapes and structures designed to disperse these waves.

The demonstrator will be used to test these capabilities in real-life conditions, enabling materials and designs to be optimised before the Tempest goes into production. The avionics systems, i.e. all the aircraft’s electronic equipment, will also be the focus of the tests. These systems, which include communication, navigation and weapons management devices, must not only perform well, but also be resilient in the face of threats such as cyber attacks.

The data gathered during the 215 hours of simulation already carried out by the test pilots is essential for refining the design of the demonstrator. These simulations make it possible to test different configurations of the aircraft and anticipate the challenges it could face in real flight.

Advances in manufacturing: towards optimised production

The Tempest project places a strong emphasis on integrating new manufacturing methods to reduce costs and lead times. BAE Systems, which is leading production, is using 3D printing techniques to create complex parts. 3D printing, or additive manufacturing, enables components to be produced directly from digital models, reducing intermediate stages and material losses.

In addition, Hot Isostatic Pressing (HIP) is used to reinforce the metal parts produced, by subjecting them to high pressure and temperature. This technique eliminates internal defects in the material, improving its strength and durability. By combining these technologies, BAE Systems hopes not only to speed up production, but also to improve the quality of the components used in the Tempest.

The aim is to create a modular aircraft capable of adapting rapidly to technological developments. This modularity will make it easy to replace obsolete or damaged components, thereby reducing maintenance costs and extending the aircraft’s lifespan.

Industrial collaboration: a project supported by a wide network of partners

The development of the Tempest demonstrator is based on close collaboration between several key players in the UK aeronautics industry. More than 100 UK suppliers are involved in the project, providing essential components and specialist services. Among them, Rolls-Royce is responsible for supplying the EJ200 engines that will power the demonstrator’s flight tests.

These engines, although based on existing technology, will be adapted to meet the specific requirements of the demonstrator, particularly in terms of performance and stealth. The choice of Rolls-Royce for this project underlines the importance of national partnerships in the development of advanced defence technologies.

MBDA UK is also working with BAE Systems to develop digital weapons integration processes. These processes, which include simulation and numerical modelling, aim to reduce the costs and timescales associated with integrating new weapons into the Tempest. This approach is crucial to ensure that the aircraft can be equipped with the most advanced weapons, while minimising technical risks.

Consequences and implications for the defence industry

The development of the Tempest demonstrator has profound implications for the UK defence industry and beyond. On a national level, the project will help to maintain and strengthen the UK’s technological and industrial capabilities, in a context where international competition in the field of military aeronautics is increasingly intense.

The production of the demonstrator is also a strong signal of the UK’s determination to remain a major player on the world stage, particularly in defence technologies. Ultimately, the Tempest could also become a strategic export for the UK, strengthening its diplomatic and economic influence.

Internationally, the Tempest project is part of a drive to modernise armed forces, where the ability to rapidly integrate new technologies has become a key factor in military superiority. The development of Tempest could inspire other nations to invest in similar projects, accentuating the race for innovation in the defence sector.

An evolving and adaptable project

Although still in the development phase, the Tempest project is designed to be scalable and adaptable. This approach means that emerging technologies, such as artificial intelligence and autonomous systems, can be progressively integrated as they mature. For example, the integration of AI could transform the Tempest into a partially autonomous aircraft, capable of making decisions in real time to optimise its mission.

What’s more, the modularity of the aircraft means that new technologies can be incorporated without having to rebuild the entire aircraft. This is particularly important in a context where threats are evolving rapidly, requiring a rapid and flexible response.

Finally, the Tempest project could also pave the way for new international collaborations. Although mainly focused on the UK, the project could attract other countries interested in developing a new generation of fighter aircraft. These collaborations could not only strengthen the technological capabilities of the partners, but also reduce development costs through economies of scale.

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