New Delhi: The Indian Air Force is significantly strengthening its maintenance network by combining domestic manufacturing with advanced technologies such as Artificial Intelligence, Digital Twins and 3D printing.
Around 930 Indian companies with expertise in mechanical, electrical, electronics and rubber manufacturing are currently contributing to the IAF’s maintenance requirements. The initiative is aimed at reducing dependence on overseas suppliers and protecting fighter operations from disruptions in global supply chains.
The IAF has already achieved substantial progress in producing frequently required spares domestically. About 97 per cent of regularly used operational spares and 93 per cent of mandatory overhaul spares have been indigenised, with approximately 62,300 components developed within India. The effort has reportedly helped save around ₹582 crore in foreign exchange over the past five years.
The force is also working with Indian MSMEs and startups on nearly 180 innovation projects under the Make, iDEX and Technology Development Fund programmes. These initiatives have generated business opportunities estimated at more than ₹17,000 crore for India’s defence manufacturing sector.
The IAF is increasingly shifting from conventional repair methods towards predictive maintenance. Digital Twins, AI and predictive analytics are being used to track equipment health and identify potential faults before they result in operational failures.
A dedicated 3D additive manufacturing facility established in 2022 is producing urgent, low volume components for aircraft and ground equipment. The facility can manufacture non critical airborne spares using aluminium, steel and titanium alloys, helping reduce dependence on foreign original equipment manufacturers.
The indigenous maintenance programme covers major fighter fleets including the Su 30MKI, Rafale, Tejas, Mirage 2000, MiG 29 and Jaguar.
The IAF is also seeking Indian industry participation for increasingly complex components, including fuel pumps, valves, hoses, control panels, radar components and other aviation systems.
Research partnerships with IITs, IISc, DIAT and MILIT are further supporting the development of advanced maintenance technologies and indigenous defence capabilities, reinforcing India’s broader Aatmanirbharta drive.
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