BAE Systems, Rolls-Royce, MBDA UK and the Ministry of Defence have revealed the design of the UK’s Combat Air Flying Demonstrator as manufacturing passes the two-thirds structural milestone. The piloted supersonic aircraft is the first of its kind to be built in the UK in 40 years.

The wings, main structure and tail fins are being developed at BAE’s Lancashire facilities using digital and robotic manufacturing techniques. The demonstrator plays a key role in testing stealth-compatible features and maturing production techniques that will feed into the Global Combat Air Programme (GCAP) with Japan and Italy.

Tony Godbold, Future Combat Air Systems delivery director at BAE Systems, says: “This significant and challenging project will deliver the UK’s first crewed combat demonstrator aircraft in four decades. The programme is accelerating the development of advanced design approaches and manufacturing techniques, helping to sharpen the UK’s industrial edge and deliver benefits beyond the production of the aircraft. As well as developing a unique aircraft, we’re building the technical foundations, workforce readiness and digital maturity essential to deliver the next generation of combat air capability.”

Richard Berthon, director Future Combat Air at the Ministry of Defence, adds: “I am delighted that today, BAE Systems and the Ministry of Defence, can share this important update on the Combat Air Flying Demonstrator. For the first time, people can see how this cutting-edge demonstrator aircraft will look when it takes to the skies. Manufacturing of the aircraft continues at pace, which is testament to the ingenuity and collaboration of Government and industry teams. The Combat Air Flying Demonstrator is providing invaluable lessons on future combat air delivery and equipping our people with the skills they will need to deliver GCAP.”

BAE test pilots, RAF crews and Rolls-Royce engineers have completed over 300 simulator hours to assess the control systems. The project is also using model-based systems engineering, 3D printing, virtual simulation and digital twins to streamline the aircraft’s eventual flight testing.