Critical Technologies India Must Master To Build AMCA Stealth Fighter Jet

India is advancing the development of its indigenous fifth-generation stealth fighter jet, the Advanced Medium Combat Aircraft (AMCA), aimed at significantly boosting its air power capabilities. The project, led by the Aeronautical Development Agency (ADA) under the Defence Ministry, involves the design and production of a medium-weight, twin-engine deep penetration stealth fighter jet equipped with advanced stealth technology, sensor fusion, AI-assisted avionics, internal weapons bays, supercruise capability, and real-time networking with unmanned aerial vehicles.

The AMCA is intended to operate alongside the Tejas Light Combat Aircraft as a core component of the Indian Air Force’s future aerial strike force.

The Indian government has initiated the process by inviting Expressions of Interest (EOI) from Indian aerospace firms—single companies, joint ventures, or consortia—for building five prototypes, which is a prerequisite preceding full-scale series production. These shortlisted companies must possess aerospace and defence industry experience and the capacity to set up manufacturing facilities for large-scale production.

The contract for development, prototyping, flight testing, and certification is expected to span no more than eight years from contract initiation. The Ministry of Defence has earmarked an estimated initial development budget of around ₹15,000 crore (~USD 1.8 billion) for this phase.

Technically, the AMCA is projected to weigh around 25 tonnes and will feature state-of-the-art systems such as modular open architecture, AI-enabled electronic piloting, advanced mission computers, integrated vehicle health management, and stealth design elements to evade radar detection. Its internal weapons bays allow it to carry precision-guided bombs and long-range air-to-air missiles while maintaining stealth.

The jet’s internal fuel capacity, extended operational range, and supercruise capability will enable sustained supersonic flight without afterburners. The fighter will also be equipped with net-centric warfare systems to coordinate operations with drones and other assets in real-time combat scenarios.

The AMCA project represents a pivotal step toward India’s self-reliance in defence manufacturing (“Atmanirbharta”) and incorporates private sector participation alongside the state-run Hindustan Aeronautics Ltd (HAL), involving major Indian industry players like Tata, L&T, Adani, and Mahindra. This expanded industrial ecosystem aims to create jobs, foster technological innovation, and potentially position India as a defence exporter in the future.

This indigenous fifth-generation stealth fighter is seen as central to modernizing the Indian Air Force and enhancing its combat capabilities in a contested environment, comparable to global fifth-generation jets such as the U.S. F-35, Russia’s Su-57, and China’s J-20.

The Development Research and Defence Organisation (DRDO) aims to deliver the AMCA by 2035, making it India’s most advanced fighter program to date. The project’s momentum has grown steadily following the success of the Tejas Light Combat Aircraft, and approval from India’s Cabinet Committee on Security has formalized the execution phase of the program.

India’s Advanced Medium Combat Aircraft (AMCA) project faces critical technological hurdles to achieve true fifth-generation fighter jet status rather than settling for a downgraded 4.5-generation platform.

Jet Engine Development: The AMCA requires a low-bypass afterburning turbofan engine producing 110–120 kN of thrust, capable of super-cruise (sustained supersonic flight without afterburner) and low infrared signature for stealth.

India currently lacks a fully indigenous fifth-generation capable engine. While foreign players like France’s Safran and the UK’s Rolls-Royce have shown interest in collaboration, a major challenge is securing full intellectual property rights for the engine to allow India long-term strategic autonomy, upgrades, and domestic production.

The existing reliance on imported US General Electric F414 engines and uncertainty over full technology transfer complicate the engine challenge.

Stealth Material And Coating: Effective stealth coatings dramatically reduce radar cross-section (RCS), a critical capability mastered only by the USA, China, and Russia. Developing stealth materials involves advanced chemical engineering, nanotechnology, and composite materials, which are closely guarded military secrets globally.

India must innovate domestically to match standards since foreign transfer is unlikely. Research like IIT Kanpur’s meta-material surface cloaking shows promise but scaling industrial production and achieving consistent stealth remain key obstacles.

Advanced Avionics And AESA Radar: The AMCA needs cutting-edge Active Electronically Scanned Array (AESA) radar to detect threats under all weather conditions with low probability of intercept.

While India has made progress on indigenous AESA radars, integrating them with AI-powered sensor fusion and stealth features for network-centric warfare is still a complex challenge demanding extensive R&D.

Internal Weapons Bay & Precision Strike Capability: To maintain stealth, AMCA must carry a payload of around 1,500 kg internally (air-to-air missiles, precision-guided munitions), avoiding external hard-points that increase radar visibility. Designing and integrating this internal weapons bay without degrading performance or aerodynamics is a difficult engineering task.

Integrated Vehicle Health Management (IVHM): Fifth-generation fighters require constant real-time monitoring of airframe, avionics, and engine health via numerous onboard sensors to enable predictive maintenance and maximum readiness. Developing a reliable IVHM tailored for India’s operational environment involves sophisticated software and sensor integration, which is both costly and complex.

Complex Manufacturing & Supply Chain: Producing a stealth fighter requires highly sensitive materials, precision manufacturing, and advanced industrial infrastructure. Historical delays in Indian projects like TEJAS MK-1 and MK-2 highlight challenges. Faster involvement of the private sector and building a robust domestic aerospace supply chain are seen as essential to meet timelines and quality standards.

India’s AMCA program is ambitious, targeting indigenous design authority with modularity, stealth shaping, super-cruise capability, AI sensor fusion, and advanced avionics.

Successful mastery of engine technology, stealth materials, avionics and radar, internal weapons integration, health monitoring, and manufacturing ecosystem will determine whether the AMCA becomes a world-class fifth-generation fighter or remains a downgraded platform.

The technological gaps are steep but combined public-private efforts and strategic international partnerships may help India clear these hurdles over the next decade.

IDN (With Agency Inputs)

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