Aircraft Division was established in the year 1940. Since inception, the Division has manufactured various types of aircrafts including fighters and trainers. The product portfolio encompasses licensed as well as indigenously designed and developed.
 
The Division is EN / AS9100 Rev D and NADCAP Certified. The Division possesses authorization to perform special processes from major OEMs such as Airbus, Boeing, Israel Aerospace Industries Ltd and BAE systems for export of aero-structures and precision aircraft components.
 
Core Competency of the Division includes Assembly, Integration, Modifications Compliance and Mid-life Upgrade of Aircraft and Integration of UAVs.
 
Current manufacturing range:
 

• Assembly, Integration and Testing:
  • Aircraft - LCA Tejas,HTT-40
  • UAV - Abhyas –HEAT
• Modifications and Mid-life Upgrade
  • Jaguar DARIN- III avionics upgrade
  • Hawk Mk-132 mid-life upgrade

 
The Division is built adjacent to HAL owned Airport facility with its own ATC facility and dedicated airspace. The Division has adequate infrastructure (2,25,000 Sq.m covered area) and is equipped with modern facilities

• Aircraft assembly hangars and Flight testing facility
• Aircraft Transparencies and Canopies
• Honeycomb Structures
• Drop Tank and Removable Role Equipment
• Sheet Metal and Welding Facilities
• ERP based Operations
• CAD / CAM based manufacturing

 
The operations of Division are supported with:

• Quality Assurance & Quality Engineering
• Methods Engineering
• Industrial Engineering
• Customer Services
• Supply Chain Management

 
With experience and capabilities built over the past eight decades, Aircraft Division is bidding for a substantial share in the global aviation arena.

• Aero-structures:
  • Major aircraft structural modules and assemblies- Metallic & Composite
  • Honeycomb sandwich bonded structures and metal to metal bonded components
  • Drop Tanks and Removable Role Equipment (Pylons and Pods)
  • Precision machined components and sub-assemblies
  • Precision sheet metal components
  • Aircraft transparencies - wind-shields and canopies

 

• UAVs:
  • Integration and Testing of UAVs

The Division has High Tech facilities under the following major heads:

• CAD / CAM:

• Tool Design- CATIA  and UNIGRAPHICS
• CNC 5 and 3 -Axis Twin spindle Aluminum Profiler
• Precision Jig & Turn Mill Centers
• CNC 5 Axis Honeycomb Carving Machine
• CNC 3-Axis Jig Boring Machine
• CNC 5-axis Machining Center
• CNC Hard Turning Center
• CNC 5-axis Laser Scriber
• Auto Deburring Machine

 

• Measuring & Test instruments:

• Co-ordinate Measuring Machines
• ‘C’ Scan Ultrasonic System
• In-Motion X-Ray Fluoroscopy
• Portable X-Ray Unit
• LASER Trackers

 

• Sheet Metal, Pipe Bending & Welding:

• CNC Stretch Forming (Sheet and Extrusions)
• Fluid Cell Forming Machine
• CNC Press Brake
• CNC Router
• Creep / Age Forming of Wing and Tail Plane Skins
• Shot Peen Forming
• CNC Pipe Bending
• Fusion Welding (TIG) Facilities
• Resistance Welding

 

• Honeycomb:

• Autoclaves
• Glass Fiber Reinforced Plastics (GRP)
• Honey Comb Machining and Bonding
• Honey Comb Bonded Panel Testing – NDT

 

• Transparencies:

• Forming of Stretched and Cast Acrylic
• Ovens (Composite & Plastics)
• Miniature Detonator Chord Assembly for Canopies
• Optical Tooling- Multi Optical Projection Systems

 

• Heat Treatment:

• Heat Treatment Furnaces – Ferrous & Non-Ferrous
• Process & Plating Facilities

 

• Process Shop:

• NADCAP Approved Plating
• Advanced Protective Treatments
• Chemical Milling

• Ion Chromatography
• Electro Static Spray Equipment
• Clean room Spray Painting facilities

 

• Wire Harness & Testing:

• Semi-Automated Loom Tester
• LASER Wire Marking Machine
• Metal and Nomax Braiding of Looms
• Automatic Cable Testing (DITMCO TEST)
• DIT-MCO Test Executive
• Health and Usage Monitoring System (HUMS)

The Light Combat Aircraft (LCA) - ‘Tejas’, is light weight, versatile, Omni-role, supersonic combat aircraft. It has been designed and developed by Aeronautical Development Agency (ADA) and HAL to meet the requirements of the Indian Air Force as its frontline, multi-mission, tactical aircraft for the coming decades.
The Aircraft is also fitted with state of the art features like glass cockpit, fly-by-wire flight control, utility services management system(USMS), Environmental control and fuel management system(ECFM), helmet mounted display system(HMDS), Radar warning receiver(RWR), counter measuring display system (CMDS), Open Architecture Mission Computer, Digital Video Recording System, Brake Control Hydraulic Engine and Electrical Monitoring System(BHEEM), Audio Management Unit, Radio Altimeter, Centralized Warning System, TACAN, VOR/ILS, Identification Friend or Foe and Air to Air refueling probe.
Composite material has been used extensively for the fuselage and the wings.
The aircraft is powered by single GE 404 IN20 turbofan engine. Tejas has four variants - Air Force (fighter & Trainer) and Naval (Fighter & Trainer).
Tejas Mark-1A is an advanced version of Mk.1 aircraft equipped with AESA Radar, AESA based SPJ, state of the Art sensor suit- Electronic Warfare (EW) with podded jammers and CMDS, CIT based IFF, smart multi-function displays (SMFD), DMG, Hot re-fueling, SDR with L Band and VHF/UHF data link for communication, ING/PS with GLONASS + IRNSS + GAGAN for navigation, additional PIB for twin launcher and long range BVRAAM. 
Features:

• Lightest in the class with 30% AUW as payload
• Relaxed static stability
• Quadruplex Digital Fly by Wire
• Glass Cockpit with Open Architecture mission computer system
• Advanced Composite Structure (90% by area and 45% by weight)

 
Roles:

• Supersonic fighter for air combat
• Offensive air support
• Reconnaissance
• Anti-shipping missions

 
Specifications:

• Length                   :           13.2 meter
• Height                    :           4.4 meter
• Wing span             :           8.2 meter
• Thrust                    :           83 KN
• MTOW                  :           13500 Kg
• Fuel capacity        :           4500kgs
• Speed                    :           1.6 Mach
• Service Ceiling      :           15 Km
• Range                   :           1800km @ 31500
• Max g                    :           + 8g / - 3.5 g

The Hawk Mk.132 Advance Jet Trainer is a transonic tandem-seat multi-purpose aircraft, powered by a single Rolls Royce Adour Mk.871 turbo fan engine.

Hawk AJT when used in its flying training role it provides basic, advanced and weapons training. The aircraft is cleared for a wide range of aerobatic maneuvers and exhibits very good resistance to departure even outside the normal flight envelope.

HAL has manufactured and delivered 99 Hawk Mk 132 aircraft to Indian Air Force and Indian Navy. HAL has the capability of providing comprehensive product support like supply of spares, aircraft servicing as per prescribed schedules including major overhaul, repair & overhaul of engine and repair of Line Replaceable Units (LRUs).

Hawk AJT aircraft is being produced by HAL as per the License grants from M/s BAE Systems and M/s Rolls Royce UK. M/s BAE Systems and M/s Rolls Royce are the License and Design authorities for Hawk Airframe and Engine respectively.
 
Salient Features:

• Tandem Dual seats
• Inertial Navigation / Global Positioning System, Head-Up Display 
• Hands-On Throttle and Stick Controls
• Single Engine
• Night flying capabilities

 
 
Roles:

• Basic Training
• Advanced Training
• Weapons Training

 
Specifications:
Wing Span                              :           9.94 m
Length                                     :           12.43 m
Height                                      :           3.98 m
Basic Empty Mass                  :           4440 kg
Max. Internal Fuel                   :           1289 kg
Max. External Load                :           3000 kg
Max. Take Off Mass              :           9100 kg
Max. Speed                            :           0.84 Mach (at Sea Level)
                                                0.85 Mach (at 30,000 ft)
Max. Service Ceiling              :           13899 m
Range with External Fuel       :           1395 nm

Obsolescence Management:

In order to provide product support for 30 years, HAL has built its own technology demonstrator aircraft (Hawk-i) for obsolescence management and upgrade activities. Apart from BAE Systems, HAL is the only facility with complete manufacturing and ROH capability of Hawk aircraft.

The following systems were integrated on Hawk Mk132 to cater for obsolescence management and capability enhancement by integration of EW systems and new weapons.

1) In-house designed Mission Computer (Both Hardware and Software) replacing existing obsolete Display Mission Computer
2) Indigenous Data Transfer System (DTS) with additional capability of Pre-Flight Message (PFM) loading replacing existing DTS
3) IFF Mk XII transponder in place of existing IFF Mk X
4) Integration of all other retained legacy systems with MC (viz MFDs, PDU&DEP, INGPS, AHRS-NSU, RADALT, INCOM (V/UHF), VOR/ILS, TACAN, SMS, ADS, HUMS and EU etc.

EW Systems: EW capability through integration of R118 RWR and CMDS

New Weapons: Integration of following conventional and smart weapons:

• 450Kg HSLD Bomb
• 500 Kg GPB
• SAAW (In Single and Twin Configuration)
• Spice 250 Kg in CLP

 

The Hindustan Turbo Trainer (HTT)-40 is an ab-initio trainer aircraft designed to meet primary training requirements. This fully aerobatic tandem seat turbo trainer will have an air-conditioned cockpit, modern avionics, hot refueling, quick pilot change over and zero-zero ejection seats. Built around a proven turbo prop engine, this aircraft is designed to have good low speed handling qualities for better training effectiveness. This aircraft will be certified to FAR-23 Standard.

The aircraft is fitted with Glass Cockpit and Indigenously developed Avionics viz Radio Communication, Standby Communication, VOR-ILS, TACAN, Radio Altimeter and Identification Friend or Foe (IFF) and Integrated Standby Instrument System (ISIS).

The HTT-40 is powered by Honeywell TPE331-12B Turboprop engine.
Salient Features:

•  Sturdy structure with a combination of light alloys and composites.
•  Single piece canopy giving both pilots good all-round vision
•  Glass cockpit
•  Maximum speed 450 km/h
•  Maximum load factor +6/-3 g
•  Glide ratio of 12.3:1

Roles:

•  General Handling
•  Aerobatics
•  Navigation
•  Instrument Flying
•  Close formation
•  Night flying

Specifications:

• Length                                                       :           10.061 meter
• Height                                                        :           3.583 meter
• Span                                                          :           11.0 meter
• Basic Empty Mass                                    :           2414 kg
• Internal fuel mass                                     :           460 kg
• Maximum Take-off Mass                         :           3040 kg
• Normal Training Configuration Mass        :           2960 kg
• Take-off Distance                                     :           785 meter
• Landing Distance                                      :           987 meter
• Time to Climb 3 km                                  :           7.05 min
• Service ceiling                                          :           6 km
• Range                                                       :           1009 km
• Endurance                                                :           3.09 hrs
• Max permissible Speed                            :           450 kmph @ 6g
• Max level Speed                                       :           407 kmph
• Max Power                                               :           1100 Shp

The Target Aircraft “ABHYAS” – High Speed Expendable Aerial Target (HEAT) system, designed and developed by DRDO’s Aeronautical Development Establishment (ADE) is programmed for fully autonomous flight using laptop-based Ground Control Station (GCS). The air vehicle is launched using twin under-slung boosters which provide the initial acceleration to the vehicle. It is powered by a gas turbine engine to sustain a long endurance flight at subsonic speed and equipped with Micro Electro Mechanical System (MEMS) based Inertial Navigation System (INS) for navigation along with the Flight Control Computer (FCC) for guidance and control.
Salient Features:

• Powered by a gas turbine engine to sustain a long endurance flight at subsonic speed.
• Equipped with a MEMS (Micro-Electro-Mechanical Systems)-based Inertial Navigation System (INS) for navigation along with the Flight Control Computer (FCC) for guidance and control.
• Programmed for fully autonomous flight and their check-out is done using a laptop-based Ground Control Station (GCS).
• Equipped with Radar Cross-Section (RCS) and infrared signatures which can be used to simulate a variety of aircraft for the practice of anti-aircraft warfare and also for the testing designed to target aerial targets.

 
Usage/Roles:

• It will be used as a target for the evaluation of various missile systems.
• The radar cross-section (RCS) as well as its visual and infrared signatures can be augmented to simulate a variety of aircraft for anti-aircraft warfare practices and testing of surface-to-air missile (SAM) systems.
• It can function as a jammer platform and decoy.

 
Salient Features:

• Speed                                :           400 kmph
• Altitude                              :           5000 m
• Maneuverability                :           2 ‘g’
• Endurance                        :           30 minutes
• Rate of Climb                    :           10 m/s
• Laptop based simple Ground Control System
• Minimum logistics requirement
• User friendly system