Pratt & Whitney, a subsidiary of RTX, has completed a fully digital assembly-readiness review for its XA103 adaptive engine. This breakthrough is a key step in the U.S. Air Force’s Next Generation Adaptive Propulsion program.

With this milestone, the company can now begin ordering hardware and prepare to assemble the first physical test engine later this decade.

This review signifies the end of an important design phase for the XA103 engine. The engine is being developed for future combat aircraft that could fly with or replace today’s stealth fighters in the 2030s. According to the firm, the XA103 will offer better fuel efficiency, improved thermal management, and more onboard power than current fighter engines.

The company completed the readiness review using only digital tools. This lets engineers simulate assembly steps, check whether manufacturing is feasible, and ensure parts fit before starting physical production. It believes this approach will reduce risks and accelerate development as the engine approaches testing.

Digital review brings engine closer to building hardware

The review demonstrated that the company’s integrated digital engineering tools work as the program moves from computer design to actual manufacturing and assembly. Jill Albertelli, president of the company’s Military Engines division, said this milestone reflects years of investment in digital tools and close collaboration with the Air Force.

“This milestone demonstrates Pratt & Whitney’s investment in digital infrastructure, showcasing seamlessly integrated digital capabilities and reinforcing our strong collaboration with the U.S. Air Force,” she added.

The company said the XA103 program is now moving into the procurement phase. This means suppliers will start making parts for the first engine. Pratt & Whitney’s NGAP team is already working with industry partners to get the hardware they need.

The digital review included simulated assembly checks, tolerance analysis, and manufacturing assessments. Engineers used advanced modeling tools to find possible problems before making any physical parts.

Adaptive engine targets better combat performance

The defense firm said the XA103 uses an adaptive engine architecture intended to improve aircraft range, survivability, and cooling capacity for future combat systems. The company also stated that the engine will handle the higher electrical power needs expected within next-generation aircraft.

Future aircraft will likely have more sensors, electronic warfare equipment, and advanced computers than today’s fighters. This means engines must handle more heat while staying fuel efficient. “As we move forward with assembling our engine for testing, our NGAP team is simultaneously developing novel digital validation tools,” Albertelli added.

“The performance we expect this engine to deliver exceeds anything available today, reinforcing the critical importance of continuous improvement and stable investment in maintaining propulsion as a strategic competitive advantage.”

The company expects the first XA103 test engine to be used for testing in the late 2020s.

GE Aerospace remains a competitor

The NGAP program is still one of the Air Force’s top propulsion development efforts. In August 2022, the Department of Defense gave both Pratt & Whitney and GE Aerospace contracts worth $975 million each for technology development and risk reduction related to NGAP.

Boeing, Lockheed Martin, and Northrop Grumman also received funding as part of the more extensive program.

The Air Force’s plan is to have two engine manufacturers compete through development and testing before choosing a final production design. The winning engine could eventually power future combat aircraft that will complement or replace the Lockheed Martin F-35 Lightning II and F-22 Raptor.