Make-in-India Rafale fuselage: A strategic move forward

First Post

12-06-2025

Rafale fuselage will be produced in India for both domestic and global markets. This marks the first time in history that Rafale fuselages will be manufactured outside France read more
In a big boost to Make-in-India, Dassault Aviation of France and India's Tata Advanced Systems Limited (TASL) will partner for Rafale aircraft fuselage manufacturing at a dedicated facility in Hyderabad. The key structural sections of the aircraft, to be manufactured in India include the central fuselage, rear section, lateral rear shells, and the front section. The first fuselage sections are expected to roll out by FY2028, with a production capacity of up to two complete fuselages per month.
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Rafale fuselage will be produced in India for both domestic and global markets. This marks the first time in history that Rafale fuselages will be manufactured outside France. Four Production Transfer Agreements (PTA) have been signed between the companies. Eric Trappier, Chairman and CEO of Dassault Aviation, emphasised that this partnership is a 'decisive step in strengthening our supply chain in India,' noting that it aligns with the company's long-term strategy to collaborate with Indian aerospace firms like TASL.
Sukaran Singh, CEO and MD of TASL, described the partnership as a milestone in India's aerospace journey, demonstrating both India's manufacturing prowess and the trust international aerospace leaders place in Indian partners. 'The production of the complete Rafale fuselage in India underscores the deepening trust in Tata Advanced Systems' capabilities and the strength of our collaboration with Dassault Aviation. It also reflects the remarkable progress India has made in establishing a modern, robust aerospace manufacturing ecosystem that can support global platforms,' Singh said.
This facility will represent a significant investment in India's aerospace infrastructure and will serve as a critical hub for high-precision manufacturing.
The Indian Air Force (IAF) has already acquired 36 Rafale and they have demonstrated their combat skills in the recent Operation Sindoor. The Indian Navy is procuring 26 maritime variants of Rafale-M. The IAF's case for 114 Multi-Role Fighter Aircraft (MRFA) procurement is in an advanced stage. Rafale is one of the contenders. Will these two developments tilt the case in favour of Rafale?
IAF transition from Mirage 2000 to Rafale was like from one dream machine to another. In the initial training for test pilots, one is taught to assess an aircraft's characteristics by just looking at it. One look at the wing-body blending, the shape of the intakes, the twist in the wing, the incline of fuselage, the size of the vertical stabilizer, the base of the wheels, all indicate great design features. France has made some great aircraft.
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Initial Aviation's French Connect
After WW-II, aviation designer Marcel Dassault re-established the aviation industry. The M.D.450 (Marcel Dassault) Ouragan was the first French-designed jet fighter-bomber to enter production. The Ouragan was later operated by France, Israel, India and El Salvador. In June 1953, India ordered 71 Ouragans (Toofani). Finally 104 were bought, and were operated by IAF till 1965. The IAF started to replace the Ouragan gradually by the Dassault Mystère IVA in 1957. India procured 104 'supersonic-in-a-dive' Mystere. The aircraft were used extensively in the Indo-Pakistani War of 1965. On 7 September 1965 an Indian Mystere, piloted by Squadron Leader Devayya shot down a Pakistani Lockheed F-104 Starfighter in a raid over Sargoda. Mystère IVs were also very successful in surface strikes. The aircraft were phased out by 1973.
Hindustan Aeronautics Limited (HAL), licence-built versions of French Aérospatiale SA 315B Lama (designated Cheetah) and Aérospatiale Alouette III (designated Chetak) in the mid-1960s. Indian Navy procured 14 French Bréguet Br.1050 Alizé in 1960 for carrier operations. French Turbomeca TM 333 2B2 engine powered initial HAL Dhruv, later replaced by the Shakti engine, which was jointly developed by HAL and Turbomeca. TM 333 2M2 powers HAL Cheetal and Chetan, upgraded versions of the Cheetah and Chetak, respectively.
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India bought the Anglo-French SEPECAT Jaguar deep penetration strike aircraft (DPSA) in late 1970s, but the contract was serviced by the British. IAF built and upgraded many Jaguars and continues to fly significant numbers even today.
Finally, IAF bought the Mirage 2000 that was inducted in 1984. It was the first relaxed stability fly-by-wire aircraft with active controls technology to induct in IAF. It also brought a modern Air Interception (AI) radar with look-down/shoot-down capabilities, and the first BVR missile, the Super R530, Later the all-aspect Magic 2 missile changed the dynamics of close combat.
IAF also got the first comprehensive EW suite on any aircraft with a self-protection jammer, RWR, chaff and flare dispenser, an escort jammer and an Elint Pod. The aircraft was later upgraded to the Mirage 2000-5 Mk 2 standards, and extended its useful life for another 20–25 years. The upgrade included a new mission computer with higher memory, new radar, advanced navigation and electronic warfare systems, advanced communication and identification systems. It also has a new glass cockpit, and helmet-mounted displays.
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Re-designated Mirage 2000I, aircraft also got the MICA air-to-air missiles. It can also carry the Israeli Spice-2000 glide bomb and the indigenous Astra AAM. Mirage 2000 performed exceedingly well in the 1999 Kargil conflict, which took place over some of the highest terrain in the world. Easy maintenance and a very high sortie rate made the Mirage 2000 one of the most efficient fighters of the IAF. Later Mirage was the chosen platform for the Balakot Strike, and took active part in Operation Sindoor.
Rafale, the Winner of MMRCA Competition
IAF needed additional medium multi-role combat aircraft (MMRCA). The aircraft in the fray for this Indian tender were Lockheed Martin F-16C/D, Mikoyan MiG-35, Saab JAS 39 Gripen, Dassault Rafale, Eurofighter Typhoon, and the Boeing F/A-18E/F Super Hornet.
The 126 aircraft were to fill the gap between the Light Combat Aircraft (LCA) and the in-service Sukhoi Su-30MKI air superiority fighter. On 27 April 2011, after an intensive and detailed technical evaluation by the IAF, two fighters, the Typhoon and Rafale, cleared technical evaluation. On 31 January 2012 it was announced that Rafale won the competition due to its lower life-cycle cost.
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The Rafale Aircraft
The French twin-engine delta-wing fighter aircraft is an omni-role fighter with frontal-stealth capabilities. It can simultaneously undertake air supremacy, interdiction, reconnaissance, and the airborne nuclear deterrent missions. Rafale was inducted in the French Air Force and for carrier-based operations in the French Navy in 2000. Rafale has been used in combat over Afghanistan, Libya, Mali, Iraq, Syria, and in Operation Sindoor.
The aircraft uses digital fly-by-wire controls and has a very high level of agility. The aircraft's canards improve aerodynamic performance. The Rafale's glass cockpit was designed around the principle of data fusion that prioritises information display to pilots. The primary flight controls are arranged in a hands-on-throttle-and-stick (HOTAS)-compatible configuration.
The Rafale also features an advanced avionics suite. The passive front-sector electro-optical system can operate both in the visible and infrared wavelengths. The total value of the radar, electronic communications and self-protection equipment is about 30 percent of the cost of the entire aircraft. The Rafale features an integrated electronic survival system named SPECTRA, which protects the aircraft against airborne and ground threats.
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The system incorporates radar warning receiver, laser-warning, Missile Approach Warning (MAW) for threat detection plus a phased array radar jammer and a decoy dispenser for threat countering. Areos all-weather, night-and-day-capable reconnaissance system used on the Rafale has the ability to transmit information such as images in real-time to ground stations. The RBE2 AA active electronically scanned array (AESA) radar has a range of 200 km.
The 36 aircraft, €7.87 billion (Rs 58,891 crore), Government-to-Government (G2G), Rafale deal included 28 single-seat, and eight twin-seat aircraft. The deal included tailor-made IAF specific enhancements including the integration of an Israeli helmet-mounted display (HMD), radar warning receivers and low-band jammers. It included a weapons package and a performance-based logistics agreement.
The aircraft's 14 hard-points can carry 9,500 kg external load. The air-to-air missiles include Matra Magic II, MBDA MICA IR or EM, and MBDA Meteor. Meteor is an active radar guided BVRAAM that offers multi-shot capability against long range manoeuvring jets, UAVs and cruise missiles in a heavy electronic countermeasures (ECM) environment with range of around 180 kilometres. The no-escape zone of over 60 km is the largest among air-to-air missiles according to the manufacturer.
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India also procured SCALP air-to-ground cruise missiles. Subsequently, the HAMMER (highly agile modular munition extended range) glide bomb was bought. The Indian Rafale is a modified version of the F3R standard. The two squadrons are located at two different air bases. Both these airbases have infrastructure and capacity for an additional squadron each.
French has already tested the F4 variant with upgraded radar, improved HMDS, OSF (long-range optoelectronics system) will add IRST for detecting and identifying airborne stealth targets at long range. It will be more effective in network-centric warfare, with more data exchange and satellite communication capacity.
Make-in-India Rafale Win-Win for India, France
Indian Navy has just ordered 26 Rafale-M, French Air and Space Force and Navy have combined orders for 286. Other operators with confirmed orders are IAF (36) Croatia (12), Egypt (54), Qatar (36), UAE (50), Indonesia (42), and Serbia (12). More orders are on the way. The current production rate is 25 aircraft a year. It will take nearly 10 years to meet existing orders. France desperately needs another production line.Production in India will be for all global customers. India's capability to make global class aero-structures has been proven with cabins of Apache AH-64, Sikorsky S-92 helicopter and Lockheed Martin C-130J Super Hercules aircraft. India also makes Lockheed Martin F-16 wings. India makes the entire indigenous Light Combat Aircraft (LCA). Making the Rafale fuselage in India will work out much cheaper for France.
Induct 114 Rafale: Best Way Ahead
Traditionally India and France have been enjoying an exceptionally warm relationship, which is the fruit of deep affinities and the unwavering trust between the two countries since India's independence. France is considered as the most reliable Western 'friend'. France has never imposed any sanctions or tried to arm-twist India. IAF regularly carries out Garuda series of air exercises with the French Air Force since 2003. The latest 'Garuda VII' was held at Jodhpur in November 2022. French air and Space Force (FASF) also participated in IAF multilateral exercise 'Tarang Shakti' in August-September 24.
IAF is already down to 30 fighter squadrons' vis-à-vis the authorised 42. India has a two-front war threat. IAF urgently needs more fighter squadrons. The Request for Proposal (RfP) for 114 new 'Make-in-India' is still to be sent out. A full-fledged selection process could take 6-8 years. Rafale is a tried and tested aircraft. India has already paid for one time India specific enhancements. We have spare capacity at existing IAF Rafale bases to take more squadrons. There is 95 per cent commonality between the IAF and Navy Rafale.
Most recent aircraft deals have all been G2G. Rafale has already been a winner of a contest in which similar competing aircraft were involved. India already has a large variety of fighter fleets. Multiple fleets are a logistical nightmare. To save time, it would be prudent to acquire 114 Rafale 4.5 generation aircraft. Initially, India would mostly make the fuselage airframe. As we go along, more sub-parts and components will be manufactured. If India chooses to make 114 Rafale for IAF, the order numbers along with the Navy would go up to 140. India could thus insist on making the entire aircraft in India. India could also tie-up with France's Safran for India's fighter aero-engine development. It will make better economic sense for IAF also to choose Rafale and acquire the latest variant F4 in a G2G deal and make it in India in larger numbers to amortise costs.
The writer is former Director General, Centre for Air Power Studies. Views expressed in the above piece are personal and solely those of the author. They do not necessarily reflect Firstpost's views.