The United Kingdom’s ambitious plan to develop a sixth-generation fighter jet is gaining momentum as its Flight Test Aircraft (FTA), nicknamed Excalibur, completes its first phase of modifications and flight testing.
A joint statement from the UK Ministry of Defense, Leonardo, and 2Excel, the two prime contractors behind the FTA, confirmed the successful completion of the initial testing phase.
Excalibur is based on a former commercial Boeing 757, which has been transformed into a cutting-edge platform for developing and testing key combat air technologies.
It is designed to serve as a “flying laboratory” to pave the way for the next-generation combat aircraft under the Global Combat Air Program (GCAP).
The GCAP, a collaborative project between the UK, Japan, and Italy, aims to combine elements of Japan’s F-X program with the UK and Italy’s Tempest initiative.
In its initial modification phase, the Excalibur FTA was outfitted with new side and belly pods, altering the aircraft’s external profile. These new fairings were subjected to stability assessments during flight to ensure their integrity and performance.
The pods are designed to host cutting-edge systems such as Integrated Sensors, Non-Kinetic Effects (ISANKE), and Integrated Communications Systems (ICS), which Leonardo is developing as part of its contributions to GCAP.
These systems are central to the ambitious effort to produce a supersonic fighter jet capable of countering modern high-level threats by 2035.
As part of its ongoing development, the Excalibur FTA will undergo further engineering work at Qinetiq’s Boscombe Down facility in Wiltshire.
The statement further said that upcoming modifications to the aircraft will include a fighter-style nose cone, specifically designed to host radar-based sensor demonstrators being developed under Leonardo’s Multi-Function Radio Frequency System program.
Excalibur is expected to carry the next-generation ISANKE and ICS technologies on board next year, allowing engineers and scientists to test and refine these systems during flight.
“This will de-risk and accelerate the domain’s development program and, in turn, support the ambitious timescales of GCAP,” the statement added.
The GCAP program is currently outperforming its competitors, with its smooth progress standing in stark contrast to the challenges faced by the USA’s Next Generation Air Dominance (NGAD) program. The NGAD has been facing escalating costs, prompting the Pentagon to reassess its strategy.
Earlier this year, Air Force Secretary Frank Kendall called for a “pause” on the Next Generation Air Dominance (NGAD) program, stating that the Air Force was uncertain whether the program’s requirements still aligned with the evolving threat landscape.
He also pointed out that the NGAD’s estimated cost—described by Kendall as “multiple hundreds of millions” of dollars per aircraft—was excessively high without additional funding.
To reassess the program, Kendall initiated an internal review and assembled a panel of former Air Force leaders with expertise in stealth projects to offer guidance.
While no specific end date for the review was set, senior leaders indicated that it would likely conclude before the Air Force submits its fiscal 2026 budget to the Office of Management and Budget.
The Role Of Boeing 757 In Modern Fighter Development
The Boeing 757, a narrow-body airliner originally designed for commercial use, has found a new life in advanced flight testing. It joins a growing list of specialized aircraft employed to test technologies for current and future-generation fighter programs.
Leonardo acquired a Boeing 757 airframe in the UK last year for its Excalibur Flight Test Aircraft (FTA) project. This aircraft, purchased from the UK charter airline Titan Airways, is now a cornerstone for a series of high-tech evaluations that support the next-generation fighter jet program.
Excalibur, named after King Arthur’s legendary sword, is planned to have a maximum payload capacity of 16 tons, which will allow it to carry substantial loads for various technological testing.
It will operate at altitudes as high as 42,000 feet, reaching speeds up to Mach 0.86. With a maximum range of 3,900 nautical miles, Excalibur can cover extensive distances, while its eight-hour endurance allows for extended testing missions.
Meanwhile, in the USA, a Boeing 757, registered as N757A, has long been a key player in avionics testing, particularly in military aircraft development.
This 42-year-old aircraft was never intended for commercial service. Instead, it was used as a prototype for various developments, both for civilian aircraft families like the 757 and, more notably, for military programs.
N757A is the first Boeing 757 to be built, and it has been involved in various testing activities over the years.
The aircraft made a key contribution to the development of the F-22 Raptor, the United States’ leading fifth-generation stealth fighter. The aircraft was used to test mock-up versions of the F-22 cockpit and avionics before the fighter jet’s maiden flight.
The aircraft’s exterior has been heavily modified to accommodate the specialized testing equipment. N757A features a sensor wing mounted on the top of the forward cabin, directly behind the flight deck.
This modification, essential for testing advanced sensor systems, is one of the aircraft’s most recognizable features.
Additionally, the plane’s nose houses an F-22 radar system. The interior was also redesigned to accommodate up to 30 software engineers, enabling them to work on the system integrations during flight tests.
While the United States and the UK utilized modified 757s for testing, China had previously turned to different aircraft for similar purposes.
The Chinese People’s Liberation Army Air Force (PLAAF) used a modified Tupolev Tu-204C, a Russian-made aircraft closely resembling the 757, as a surrogate testbed for its J-20 stealth fighter.
In 2015, a PLAAF Tupolev Tu-204 was seen sporting a nose cone from the J-20 fighter, indicating its role in testing the J-20’s advanced avionics systems. At the time, it was believed that the aircraft housed the Type 1475 (KLJ-5) active electronically scanned array (AESA) radar, a component for improving the J-20’s sensor capabilities.
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