The HAL Tejas Program

The HAL Tejas Program: Progress, Challenges, and Future Prospects

The Hindustan Aeronautics Limited (HAL) Light Combat Aircraft (LCA) Tejas is a cornerstone of India’s defense modernization and its push for self-reliance under the “Make in India” and “Aatmanirbhar Bharat” initiatives. Designed by the Aeronautical Development Agency (ADA) and manufactured by HAL, the Tejas is a single-engine, multirole supersonic fighter aimed at bolstering the Indian Air Force (IAF) while reducing dependence on foreign imports. However, the program has faced significant challenges, including delivery delays, engine supply constraints, and quality concerns, raising questions about HAL’s ability to meet IAF’s urgent needs. This blog explores the Tejas program’s current status, its technological advancements, strategic importance, and future trajectory, addressing key aspects such as deliveries, production capacity, indigenization, avionics, armaments, costs, and comparisons with peers.

Abstract  The Hindustan Aeronautics Limited (HAL) Light Combat Aircraft (LCA) Tejas program is pivotal to India’s defense modernization and self-reliance goals under “Aatmanirbhar Bharat.” As of May 2025, HAL has delivered approximately 40 LCA Mk-1 aircraft to the Indian Air Force (IAF), with 83 Mk-1A aircraft contracted and 97 more pending. Production capacity stands at 24 aircraft annually, constrained by General Electric’s delayed F404 engine deliveries, prompting exploration of indigenous Kaveri and F414 ToT alternatives. The Mk-1A, with 65% indigenous content, features advanced avionics like the EL/M-2052 AESA radar and indigenous EW suites, developed by DRDO and BEL. Designed as a 4.5-generation multirole fighter, it replaces aging MiG fleets, supports air superiority, ground attack, and potential exports. Armaments include Astra, Derby, and Spice-2000 munitions. However, HAL’s delivery delays, quality issues, and IAF’s squadron shortage raise concerns, necessitating diversified supply chains and private sector integration. Costing ~₹550 crore per Mk-1A, the program has seen ~₹73,202 crore invested, with ₹92,000–97,000 crore projected over 2025–2030. Despite challenges, the Tejas’ competitive edge against peers like JF-17 underscores its strategic importance, provided HAL addresses bottlenecks to ensure timely deliveries and operational readiness.

 

---

1. Deliveries to the Indian Air Force: Current Status

As of May 2025, HAL has delivered approximately 40 LCA Tejas Mk-1 aircraft to the IAF, comprising:

• 20 aircraft in Initial Operational Clearance (IOC) configuration.
• 20 aircraft in Final Operational Clearance (FOC) configuration, including 32 single-seat fighters and 8 twin-seat trainers.

These deliveries stem from two contracts signed in 2006 and 2010, worth ₹2,813 crore and ₹5,989 crore, respectively. The IAF has operationalized two squadrons: No. 45 Squadron (“Flying Daggers”) and No. 18 Squadron (“Flying Bullets”), based at Sulur Air Force Station, Tamil Nadu.

For the LCA Mk-1A, an advanced variant, HAL has not yet delivered any aircraft as of March 2025, though 2–3 aircraft were expected by the end of FY 2024-25. Delays, primarily due to engine supply issues from General Electric (GE), have pushed the first delivery to mid-2025.

Inference: The delivery of 40 Mk-1 aircraft over two decades reflects slow progress, constrained by technological challenges and supply chain issues. The IAF’s operational squadrons demonstrate the aircraft’s combat readiness, but the delay in Mk-1A deliveries is a critical concern given the IAF’s depleting squadron strength (31 against a sanctioned 42).

---

2. Expected Deliveries in the Next 5 Years (2025–2030)

HAL is contracted to deliver 83 LCA Mk-1A aircraft (73 fighters and 10 trainers) under a ₹48,000 crore deal signed in February 2021. A tender for an additional 97 Mk-1A aircraft, worth approximately ₹67,000 crore, is expected to be finalized by late 2025. Assuming production stabilizes, the delivery outlook for the next 5 years (FY 2025-26 to FY 2029-30) is:

• 83 Mk-1A Order: HAL aims to deliver 16–24 aircraft annually, completing this order by FY 2028-29. At an average of 20 aircraft per year, approximately 80–100 aircraft could be delivered by 2030.
• 97 Mk-1A Order: If finalized, deliveries may commence by FY 2028-29, potentially adding 10–20 aircraft by FY 2029-30.
• Total Estimate: 90–120 LCA Mk-1A aircraft over the next 5 years, contingent on resolving engine supply bottlenecks and scaling production.

Inference: The ambitious delivery targets hinge on HAL’s ability to streamline its supply chain and GE’s commitment to engine deliveries. The additional 97-aircraft order could significantly boost IAF’s capabilities, but delays in finalizing the contract may compress timelines.

---

3. Production Capacity: Scaling Up

HAL’s current production capacity for LCA Tejas is 24 aircraft per year, supported by:

• Two assembly lines in Bengaluru, each producing 8 aircraft annually.
• One assembly line in Nashik, operational since 2024, with a capacity of 8 aircraft per year.

A fourth assembly line in Nashik is planned, which could increase capacity to 30–34 aircraft annually, but its establishment will take 1.5 years and depends on consistent engine supplies. Private sector involvement (e.g., Tata Advanced Systems, L&T) in component manufacturing could further enhance output.

Inference: HAL’s expansion to 24 aircraft per year is a significant step, but achieving higher rates requires robust supply chains and private sector integration. The proposed fourth line underscores HAL’s long-term commitment but highlights the immediate bottleneck of engine availability.

---

4. Engine Supply Constraints from General Electric

The LCA Mk-1 and Mk-1A are powered by the GE F404-IN20 engine, which has been a major bottleneck:

• Historical Context: GE delivered 65 F404-IN20 engines by 2016 for the 40 Mk-1 aircraft. With no further orders until 2021, the production line was shut down, causing delays when HAL ordered 99 engines for the Mk-1A.
• Current Delays: Supply chain disruptions, exacerbated by the COVID-19 pandemic and GE’s prioritization of other projects, led to a two-year delay. As of January 2025, GE had a backlog of 26 engines, with the first engine delivered in March 2025.
• Delivery Schedule: GE has committed to delivering 12 engines in 2025 and 20 engines annually from 2026 onward.
• Geopolitical Risks: Dependence on U.S.-supplied engines raises concerns about potential leverage over India’s foreign policy, as noted in defense discussions.

Backup Plans:

• HAL has used Category-B (reserve) engines for trials and demonstrations, but these are not suitable for operational deliveries.
• The Kaveri engine, developed by DRDO’s Gas Turbine Research Establishment (GTRE), was initially intended for the LCA but failed to meet thrust requirements. It is now repurposed for UAVs, with renewed funding to develop a Kaveri 2.0 for future platforms like the Tejas Mk-2 or Ghatak UCAV.
• For the Tejas Mk-2 and Advanced Medium Combat Aircraft (AMCA), HAL is negotiating an 80% Transfer of Technology (ToT) deal with GE for the F414 engine, enabling local production to reduce dependency. Production is expected to start within 2–3 years of contract signing (likely by 2026).
• Discussions with France (Safran) and UK (Rolls-Royce) for alternative engine partnerships have been suggested to diversify supply chains.

Inference: GE’s delays have significantly hampered the Mk-1A program, underscoring the risks of single-vendor dependency. The ToT deal for F414 engines and renewed Kaveri efforts are promising, but India must prioritize dual-vendor strategies to mitigate future risks.

---

5. Indigenization Component: A Push for Self-Reliance

The LCA program is a flagship of India’s indigenization drive:

• LCA Mk-1: Approximately 52% indigenous content, including airframe components, some avionics, and systems developed by HAL, DRDO, and private firms.
• LCA Mk-1A: Targeted at 65% indigenous content, with:
• Indigenous systems like flight control computers, air data computers, and electronic warfare suites from DRDO and BEL.
• Private sector contributions (e.g., VEM Technologies, Dynamatic, L&T) for fuselage and structural components.
• LCA Mk-2: Expected to achieve 75–82% indigenization, with localized F414 engine production and advanced indigenous avionics like the Uttam AESA radar.

Challenges: Critical components like the GE F404 engine, EL/M-2052 AESA radar (Israel), and some sensors remain imported, limiting indigenization. The Kaveri engine’s failure highlights gaps in high-end technology development.

Inference: The increase from 52% to 65% indigenization is commendable, but achieving 75%+ for Mk-2 requires significant investment in R&D and private sector ecosystems. Dependency on foreign engines remains a strategic vulnerability.

---

6. Avionics: Cutting-Edge Technology

The LCA Mk-1A features a 4.5-generation avionics suite, enhancing its multirole capabilities:

• Radar: EL/M-2052 AESA radar (Israel), with superior target detection, tracking, and jamming resistance. Future batches may integrate the indigenous Uttam AESA radar.
• Electronic Warfare (EW) Suite: Indigenous Angad EW suite and DRDO Advanced Self-Protection Jammer (ASPJ), including radar warning receivers (RWR) and missile approach warning systems.
• Flight Control: **Digital Digital Flight Control Computer for enhanced maneuverability and stability.
• Cockpit: Glass cockpit with multifunction displays, head-up display (HUD), and Hands-On-Throttle-And-Stick (HOTAS) for reduced pilot workload.
• Communication: Software Defined Radio (SDR) for secure, network-centric warfare.
• Other Systems: Onboard Oxygen Generation System (OBOGS) and in-flight refueling for extended endurance.

Developers:

• Bharat Electronics Limited (BEL): Supplies flight control computers, air data computers, weapon computers, RWR, and HUD under a ₹2,400 crore contract (2023–2028).
• DRDO: Through ADA, Aeronautical Development Establishment (ADE), Combat Aircraft Systems Development and Integration Centre (CASDIC), and Central Scientific Instruments Organisation (CSIO), develops EW suites and other avionics.
• Private Firms: Astra Microwave Products and others supply sensors and electronics.
• Foreign Suppliers: Israel Aerospace Industries (IAI) for the EL/M-2052 radar; other imported components from global OEMs.

Inference: The Mk-1A’s avionics rival those of modern 4.5-generation fighters, enabling multirole operations. Indigenous development by BEL and DRDO enhances self-reliance, but reliance on Israeli radar highlights gaps in domestic radar technology.

---

7. Envisaged Role: Backbone of the IAF

The LCA Tejas is designed as a lightweight, multirole fighter to:

• Replace Aging Fleets: Phase out MiG-21, MiG-23, and MiG-27 aircraft, addressing the IAF’s squadron shortage.
• Air Superiority: Engage in beyond-visual-range (BVR) and close-combat missions with missiles like Astra and Derby.
• Ground Attack: Conduct precision strikes with Spice-2000, SAAW, and other munitions.
• Maritime Operations: Support anti-ship roles (though the Navy focuses on the Twin Engine Deck Based Fighter, TEDBF).
• Export Potential: Position India as a defense exporter, with interest from Argentina, Egypt, and Botswana.

The Tejas is central to the IAF’s modernization, aiming to operate 350 aircraft (Mk-1, Mk-1A, Mk-2) by the 2030s, forming a third of its fleet alongside Su-30 MKI, Rafale, and AMCA.

Inference: The Tejas is strategically vital for India’s air defense and geopolitical positioning, countering threats from China and Pakistan. Its export potential could boost India’s defense industry, but operational success depends on timely deliveries.

---

8. Armaments: Versatile Payload

The LCA Mk-1A has a payload capacity of 3,500 kg across 7–8 hardpoints, carrying:

• Air-to-Air Missiles:
• Astra: Indigenous BVR missile (100+ km range).
• Derby: Medium-range BVR missile.
• Python-5: Short-range IR-guided missile.
• R-73: Russian short-range missile.
• Air-to-Ground Munitions:
• Spice-2000: Precision-guided bomb.
• SAAW: Indigenous smart anti-airfield weapon.
• Crystal Maze: Stand-off missile.
• Conventional bombs and 70mm rocket pods.
• Anti-Ship Missiles: Potential integration with BrahMos-NG.
• Gun: 23mm GSh-23 twin-barrel cannon.
• Other: Drop tanks and mid-air refueling probe for extended range.

Inference: The Mk-1A’s armament suite supports diverse missions, with indigenous weapons like Astra and SAAW enhancing self-reliance. Future integrations (e.g., BrahMos-NG) could further expand its capabilities.

---

9. Concerns Over HAL’s Delivery Schedules

The IAF has expressed significant concerns about HAL’s ability to meet delivery timelines:

• Delays: The Mk-1A’s first delivery, initially scheduled for March 2024, has been delayed to mid-2025 due to engine supply issues and certification challenges.
• IAF Frustration: Air Chief Marshal AP Singh publicly criticized HAL at Aero India 2025, stating, “I have no confidence in HAL,” citing unfulfilled promises of delivering 11 Mk-1A aircraft by February 2025.
• Squadron Shortage: The IAF’s 31 squadrons (against 42 sanctioned) face further depletion with the phasing out of MiG-21s, making timely Tejas deliveries critical.
• Quality Issues: Technical snags during trials and slow production rates have raised doubts about HAL’s reliability.

Should India Be Worried?Yes, India should be concerned. HAL’s track record of delays, coupled with the IAF’s operational constraints, poses risks to national security. The Parliamentary Committee on Defence (December 2024) described the squadron shortage as “worrisome.” However, HAL’s efforts to expand production lines and engage private partners show commitment to improvement. The involvement of the Prime Minister’s Office (PMO) and high-level engagements with GE indicate government prioritization.

Inference: HAL’s delays are a significant bottleneck, but its strategic importance and ongoing reforms suggest potential for recovery. The IAF’s push for public-private partnerships (PPP) could diversify production, but immediate action is needed to restore confidence.

---

10. Comparison with Other Aircraft in Its Category

The LCA Tejas Mk-1A is a 4.5-generation light fighter, competing with aircraft like:

• Saab Gripen E/F (Sweden):
• Similarities: AESA radar, multirole capabilities, lightweight design (8,000 kg empty weight).
• Differences: Gripen has a more mature design, higher thrust-to-weight ratio (GE F414 engine), and proven export success (Brazil, Thailand). Tejas is cheaper but less combat-tested.
• KAI FA-50 (South Korea):
• Similarities: Light multirole fighter, GE F404 engine, modern avionics.
• Differences: FA-50 is primarily a trainer/light attack aircraft with lower payload (2,800 kg) and less advanced EW suite. Tejas offers greater multirole flexibility.
• JF-17 Thunder (Pakistan/China):
• Similarities: Lightweight, multirole, comparable payload (~3,800 kg).
• Differences: JF-17 uses a Chinese RD-93 engine with reliability concerns. Tejas has superior avionics (AESA vs. mechanically scanned radar) and indigenous systems, giving it an edge in network-centric warfare.
• F-16 Block 70/72 (USA):
• Similarities: Multirole, AESA radar, extensive weapons suite.
• Differences: F-16 is heavier (9,500 kg), more expensive (~$60 million), and combat-proven. Tejas is more cost-effective but less versatile in heavy strike roles.

Inference: The Tejas Mk-1A holds its own against light fighters like Gripen and FA-50, with competitive avionics and cost advantages. However, it lags in combat experience and engine maturity compared to Gripen or F-16. Against the JF-17, Tejas has a technological edge, crucial for India-Pakistan scenarios.

---

11. Cost and Investment

Cost per Aircraft

• LCA Mk-1: Approximately ₹200–250 crore (~$25–30 million) per unit, based on 2006/2010 contracts.
• LCA Mk-1A: Estimated at ₹550–600 crore (~$65–70 million) per unit, reflecting advanced avionics and inflation. The 83-aircraft contract (₹48,000 crore) averages ₹578 crore per aircraft.
• Export Cost: HAL estimates ₹84 billion (~$1 billion) for 18 aircraft, or ~$55 million per unit, competitive with Gripen (~$85 million) and FA-50 (~$35 million).

Invested Amount So Far

• Development Costs: The LCA program, initiated in 1983, has incurred ~₹14,000 crore in R&D and prototyping costs (up to 2021), managed by ADA and DRDO.
• Production Contracts:
• 2006/2010 (40 Mk-1): ₹8,802 crore.
• 2021 (83 Mk-1A): ₹48,000 crore.
• BEL Avionics (2023–2028): ₹2,400 crore.
• Total: ~₹59,202 crore (~$7.5 billion) for production and avionics.
• Total Investment: ~₹73,202 crore (~$9 billion), including development and production.

Expected Investment (2025–2030)

• 97 Mk-1A Order: ₹67,000 crore (pending finalization).
• Mk-2 Development: Estimated at ₹10,000–15,000 crore for prototypes, testing, and production setup (first flight by 2028).
• Engine ToT (F414): ~₹10,000 crore for production facilities and licensing.
• Kaveri 2.0 and Infrastructure: ~₹5,000 crore for R&D and new assembly lines.
• Total: ₹92,000–97,000 crore (~$11–12 billion) over the next 5 years.

Inference: The Tejas is cost-competitive globally, offering a viable alternative to imported fighters. The ~$9 billion invested reflects India’s long-term commitment, but the projected $11–12 billion investment underscores the need for efficient fund utilization and private sector involvement to maximize returns.

---

12. Conclusions 

The HAL Tejas program is a testament to India’s growing aerospace capabilities but faces significant challenges that require urgent action:

• Achievements: Delivery of 40 Mk-1 aircraft, operational squadrons, and a 65% indigenized Mk-1A with advanced avionics demonstrate progress. The Tejas is poised to be the IAF’s backbone, with export potential.
• Challenges: Engine supply delays, slow production, and quality concerns have eroded IAF confidence. The squadron shortage and geopolitical tensions necessitate rapid scaling.
• Requirements:
• Diversify Engine Supply: Finalize the F414 ToT deal and explore partnerships with Safran or Rolls-Royce to reduce GE dependency.
• Enhance Production: Operationalize the fourth Nashik line and integrate private players (e.g., Tata, L&T) via PPP models to achieve 30+ aircraft annually.
• Accelerate Indigenization: Invest in indigenous radar (Uttam) and Kaveri 2.0 to reach 75%+ indigenization.
• Strengthen Oversight: Establish a dedicated task force under the PMO to monitor HAL’s delivery schedules and quality.
• Boost Exports: Leverage Argentina’s interest to secure orders, enhancing economies of scale.

Final Inference: The Tejas program is at a critical juncture. While it embodies India’s self-reliance aspirations, HAL’s delivery delays and engine constraints threaten its strategic goals. With robust reforms, diversified supply chains, and increased private sector involvement, the Tejas can strengthen India’s air power and global defense stature. Failure to address these challenges risks undermining the IAF’s combat readiness and India’s geopolitical positioning.

---

References

1. HAL Tejas - Wikipedia.
2. Will Streamlining Supply Chain Help HAL Deliver Delayed Tejas Aircraft To Indian Air Force? - Forbes India.
3. HAL to start deliveries of Tejas Mk-1A to IAF by end of 2025 - Financial Express.
4. Tejas jets engines - US GE aerospace delivers first of Tejas Mk1A engines - India Today.
5. HAL stumbles, IAF struggles: Where is India's Tejas fleet? – Firstpost.
6. BEL receives biggest avionics order ever from HAL for LCA Tejas Fighter Aircraft programme - BEL.
7. HAL To Deliver 24 Tejas Mk-1A Annually From 2025-26 - Swarajya.
8. Looking beyond HAL, IAF proposes public-private partnership to ramp up Tejas production line - The Print.
9. After delays, GE Aerospace announces delivery of jet engines for Tejas LCA-Mk1A - The Hindu.
10. US firm behind delay in LCA Tejas Mk1A deliveries to IAF - Business Standard.
11. Posts on X by @TheLegateIN, @AdvaityaC.