In a shift from traditional procurement timelines, the U.S. Army is targeting 2028 to deliver its next-generation assault aircraft to soldiers. This accelerated schedule hinges on a calculated strategy to enter low-rate production of the Future Long-Range Assault Aircraft (FLRAA) while prototypes are still undergoing testing, a move intended to equip units with the advanced tiltrotor years earlier than initially planned.
A New Approach to Production
The plan represents a key component of the Army’s broader transformation initiative. Traditionally, military procurement involves a lengthy and sequential process: prototypes are built, they undergo a rigorous testing phase that lasts roughly two years, and only after the results are analyzed is a decision made to begin production.
The Army, however, is compressing this timeline for the FLRAA. “Normally, you would build prototypes, then you would go to test,” stated Col. Jeffrey Poquette, the Army’s FLRAA program manager. “What we can do is assume a little bit of risk and say, well, maybe we can build aircraft during the test.”
Mitigating Risk with Digital Engineering
This strategy of producing a system before its final design is fully validated through testing is historically filled with risk, having led to delays and cost overruns in past programs. However, both Army and Bell officials express confidence that this time is different, mainly due to advancements in digital design and engineering.
Bell has provided assurances to the Army regarding the high fidelity of its digital models. “Bell has assured the Army that it is ‘very confident’ in its digital engineering to the point that, ‘although it may not be perfect, it’ll be pretty close,'” Poquette noted.
This confidence stems from the extensive groundwork laid during the preceding technology demonstration phase, where Bell’s V-280 Valor prototype flew for over 200 hours. Ryan Ehinger, Bell’s FLRAA program manager, described the move to production as a “continuation” and an “iteration” of the manufacturing processes developed over the years. Bell has been refining the manufacturing of critical components, such as the aircraft’s wings, blades, and gearboxes, at its technology center.
Accelerating Fielding Across the Force
The benefits of this accelerated approach extend beyond the first delivery. The Army is also pushing Bell to ramp up its manufacturing capacity more quickly to achieve full-rate production in four or five years, a significant reduction from the typical seven or eight years.
This faster production rate is expected to have a cascading effect on fielding. “That means we get a company a year earlier, but we get a battalion 18 months earlier and we get two battalions 30 months earlier,” explained Poquette.
Furthermore, this strategy could accelerate the timeline for the crucial Initial Operational Test and Evaluation (IOT&E) phase. With production aircraft available sooner, the IOT&E could potentially commence in the 2028 or 2029 fiscal year, a notable acceleration from the original projection of late fiscal year 2031. This would allow the Army to validate the aircraft’s capabilities under realistic operational conditions much sooner, marking a critical step in declaring the platform ready for the modern battlefield.
