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PBS Aerospace Opens Turbojet Engine Facility In Georgia

PBS TJ40 engine. (Photo: PBS Aerospace)

PBS TJ40 engine. (Photo: PBS Aerospace)

PBS TJ40 engine. (Photo: PBS Aerospace)

PBS Aerospace, a business of Czech-based engineering company PBS Group, on Sept. 4 established its headquarters in Georgia, where the turbojet engine manufacturer also opened a new facility to build propulsion systems for drones and advanced munitions to meet rising Defense Department demand.

The new manufacturing facility will be able to build several thousand small turbojet engines annually beginning in 2026, PBS Aerospace said. The company will build the 100-pound thrust class TJ40 and 200-pound thrust class TJ80 engines in Roswell, Erin Durham, CEO of PBS Aerospace, told sister publication Defense Daily in an interview on Aug. 29.

The small, lightweight, affordable engines are designed for drones, interceptors, and cruise missiles.

PBS Group currently supplies hundreds up to about 1,000 engines per year to U.S. customers, Durham said. Opening a manufacturing facility in the U.S. will better help the company meet growing demand here, he said.

“The U.S. is a cornerstone of our growth strategy,” Petr Kadner, CEO of PBS Group, said in a statement. “Expanding production here allows us to accelerate deliveries, deepen collaboration with American partners and invest in the innovations our customers require.”

Customers for the company’s U.S.-built engines have not been disclosed. PBS Aerospace currently has 50 employees and will be expanding to 100 over the next six to nine months, Durham said.

PBS Group said it made a multi-million dollar investment to establish the new facility and plans to invest another $90 million to expand production capacity over the coming years.

“The expansion will include the development of a new plant designed to further increase output of small turbojet engines for unmanned systems, cruise missiles, and advanced aerial platforms,” PBS Group said.

A version of this story originally appeared in affiliate publication Defense Daily.

The post PBS Aerospace Opens Turbojet Engine Facility In Georgia appeared first on Avionics International.

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Sky Under Siege: Digital Attacks Forcing a New Era in Avionics Cybersecurity

Global Avionics Round-Up from Aircraft Value News (AVN)

(Photo: ICAO)

Cybersecurity is no longer a back-office concern for airlines and aircraft operators. It has become a frontline issue, with the rise of sophisticated digital threats targeting avionics systems directly affecting flight safety.

Among the most alarming of these threats is GPS spoofing, a form of digital manipulation where false signals are sent to aircraft navigation systems.

These attacks have the potential to mislead pilots and automated systems, steering planes off course. In most cases, the disruption can be managed with timely intervention from Air Traffic Control, but the growing frequency of incidents has industry experts sounding the alarm.

Recent data from the OpsGroup, a membership organization dedicated to international flight operations, highlights just how steep this surge has become. According to their latest figures, the number of GPS spoofing incidents has increased by a staggering 400% so far this year. That translates to roughly 900 flights encountering potential GPS interference each day.

The sheer scale of this increase raises the stakes for operators, regulators, and passengers alike, and signals that traditional risk mitigation strategies may no longer be sufficient on their own.

GPS spoofing is just one facet of a broader wave of cyber threats targeting aviation. The digital transformation of airlines, airports, and air traffic systems has created new vulnerabilities, and cybercriminals are taking notice.

According to research conducted by cybersecurity services firm Bridewell, more than half of civil aviation cybersecurity leaders in the United States—55%—reported experiencing ransomware attacks over the past year. These attacks can lock critical systems, threaten operational continuity, and demand significant financial or data concessions to resolve.

The industry’s growing dependence on digital technology and automation has intensified the consequences of such attacks. Modern aircraft rely on interconnected systems for everything from navigation to engine monitoring, and airlines increasingly use cloud-based platforms for maintenance scheduling, crew management, and passenger services.

Any breach in these systems can ripple across operations, creating delays, financial losses, and potential safety hazards. For operators, the challenge is not only detecting and responding to cyber incidents but also anticipating and preventing them before they occur.

Cybersecurity Investments on the Rise

To meet these challenges, aviation organizations are scaling up their cybersecurity investments. Bridewell’s survey indicates that 72% of respondents plan to increase IT security budgets compared with the previous year, with much of that funding devoted to creating protections for avionics.

This surge in spending reflects a recognition that cybersecurity is now a core component of operational safety rather than a peripheral concern. Airlines and operators are deploying a range of solutions, from advanced firewalls and intrusion detection systems to real-time monitoring tools capable of identifying unusual activity in avionics networks.

Artificial intelligence has emerged as a key ally in this effort. According to the same survey, 98% of aviation cyber decision-makers are now leveraging at least one AI-driven tool to bolster their defenses.

These systems can analyze vast amounts of data from flight operations, detect anomalies, and provide predictive insights, helping operators identify potential threats before they escalate. AI is particularly useful in addressing GPS spoofing attacks, where subtle deviations in navigation signals can be difficult for human operators to detect in real time.

The convergence of digitalization and cybersecurity investment is creating a new paradigm in aviation operations. Aircraft systems are becoming smarter and more interconnected, while security frameworks are evolving to match.

Operators are beginning to view cybersecurity as an integral part of avionics design, rather than a reactive add-on. Industry collaboration is also expanding, with regulators, aircraft manufacturers, airlines, and cybersecurity firms sharing threat intelligence and best practices to strengthen defenses across the aviation ecosystem.

Despite these efforts, experts caution that cyber risks will continue to evolve. GPS spoofing methods are becoming more sophisticated, ransomware actors are constantly refining their tactics, and the rapid adoption of new digital tools can inadvertently introduce additional vulnerabilities. This makes continuous vigilance and investment critical.

For aviation stakeholders, the focus is shifting from simply responding to attacks toward creating resilient systems capable of absorbing and mitigating threats while maintaining operational continuity.

The stakes are high because the consequences of a cyber incident in aviation can extend far beyond delayed flights or financial losses. Safety, public confidence, and international air traffic stability are all on the line. As the industry continues to digitalize, ensuring robust cybersecurity measures is no longer optional. It is a strategic imperative that requires sustained investment, innovation, and collaboration.

In this new environment, the line between traditional avionics engineering and cybersecurity expertise is blurring. Protecting aircraft and passengers now depends as much on software, data analytics, and AI-driven defense systems as it does on engines, wings, and navigation instruments.

The rise in GPS spoofing and ransomware attacks underscores the reality that modern aviation operates in a digital sky that must be defended as rigorously as its physical one.

The aviation industry is learning that staying ahead of cyber threats is not a temporary project but a continuous mission. Airlines, manufacturers, and regulators are increasingly aligned in their efforts to create resilient systems, enhance detection capabilities, and embed cybersecurity into every aspect of flight operations.

This article originally appeared in Aircraft Value News.

John Persinos is the editor-in-chief of Aircraft Value News.

The post Sky Under Siege: Digital Attacks Forcing a New Era in Avionics Cybersecurity appeared first on Avionics International.

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Honeywell and NXP Forge Path to AI-Driven Autonomous Aviation

Global Avionics Round-Up from Aircraft Value News (AVN)

Honeywell first unveiled its new Anthem integrated flight deck in 2021. (Photo: Honeywell Aerospace)

Honeywell and NXP Semiconductors are taking a major step toward the future of autonomous flight by deepening their partnership to develop artificial intelligence-driven aerospace technology.

At the heart of this collaboration is the integration of NXP’s domain-based architecture, which combines high-performance computing with robust cybersecurity, into Honeywell Anthem, the aviation industry’s first cloud-connected cockpit system. The move signals a push toward cockpits capable of sensing, analyzing, and acting with autonomy.

Honeywell Anthem has already impressed OEMs, pilots and industry analysts as a cockpit system that connects aircraft to the cloud, enabling real-time monitoring and predictive analytics. By incorporating NXP’s i.MX 8 processors and S32N safety controllers, Anthem will gain faster data processing and enhanced AI capabilities.

This allows the system to generate real-time insights that improve flight safety, streamline pilot decision-making, and lay the groundwork for semi-autonomous or fully autonomous flight operations. The collaboration highlights a shift in the aerospace industry from incremental avionics upgrades to deeply integrated, AI-driven platforms.

Moving avionics closer to autonomous flight requires a blend of high-performance computing, AI, advanced connectivity, and functional safety. NXP’s broad systems solutions portfolio positions the company as a strategic partner for Honeywell as it pushes to create avionics that can sense, think, and act.

Cognitive Platforms

Essentially, the cockpit is evolving from a control interface into a cognitive platform capable of assisting or even taking over specific operational tasks.

The implications of this partnership extend beyond technical integration. Electric Vertical Take-Off and Landing (eVTOL) aircraft developer Vertical Aerospace plans to leverage the combined technologies while testing its VX4 prototype, which features Honeywell Anthem. This suggests a growing convergence between traditional avionics leaders and emerging electric aircraft developers.

For urban air mobility and other next-generation flight markets, faster, AI-enabled data processing means improved trajectory optimization, better predictive maintenance, and enhanced situational awareness. In practical terms, this could reduce delays, enhance passenger safety, and accelerate certification processes for autonomous aircraft.

Beyond real-time data processing, the collaboration aims to tackle some of the industry’s long-standing challenges. Honeywell and NXP plan to advance large-area cockpit displays with improved visual clarity and system efficiency.

In AI-piloted aircraft, clear and intuitive displays are critical. They not only provide pilots with actionable information in high-pressure scenarios but also serve as interfaces for autonomous systems to communicate with human operators. By focusing on display innovation, the partnership is addressing both human factors and machine-to-human interaction, which is a dual requirement for safe autonomous operations.

The companies are also exploring ways to simplify migrations to newer avionic technologies. Legacy systems often create bottlenecks for innovation because integrating AI and autonomous functions into older platforms can be costly and time-consuming.

By designing architectures that are modular and scalable, Honeywell and NXP aim to make it easier for operators to adopt next-generation avionics without extensive downtime or expensive retrofits. This approach aligns with broader industry trends that emphasize flexibility, scalability, and long-term technology sustainability.

A Holistic Integration

Lifecycle extension for critical aviation technologies is another area of focus. In an era when avionics systems are expected to remain in service for decades, maintaining relevance while introducing AI capabilities is a delicate balancing act.

By combining Honeywell’s avionics expertise with NXP’s high-compute, secure processing, the partnership is positioned to support aircraft systems that evolve alongside the broader AI and autonomy landscape. This means aircraft could see improved operational longevity, lower maintenance costs, and a smoother transition to increasingly autonomous flight operations.

For analysts and industry observers, this collaboration offers an early glimpse into what AI-piloted aircraft could look like. Real-time AI insights integrated into cockpit systems enhance decision-making in ways that human pilots alone can’t match. This could include automatic route adjustments in response to weather or air traffic, predictive monitoring of mechanical systems, or real-time optimization of energy use in electric aircraft.

The Honeywell-NXP partnership represents a bridge between current human-piloted aircraft and a future where aircraft can operate with a high degree of autonomy without compromising safety.

Ultimately, this move underscores how AI is reshaping aerospace. The integration of high-performance processors, cloud-connected systems, and secure architectures is creating cockpits that are smarter, faster, and more resilient.

As Honeywell and NXP work together to refine Anthem for AI-driven flight, the industry is moving closer to a world where autonomous and semi-autonomous aircraft are not just experimental but commercially viable. The partnership signals a broader trend: successful autonomous flight will require not just AI, but a holistic integration of hardware, software, connectivity, and human-machine interface design.

Honeywell Anthem, powered by NXP, may not yet be flying fully autonomous passenger aircraft, but it is laying the technological foundation for a future where aircraft can think, learn, and respond in real time.

This article originally appeared in Aircraft Value News.

John Persinos is the editor-in-chief of Aircraft Value News.

The post Honeywell and NXP Forge Path to AI-Driven Autonomous Aviation appeared first on Avionics International.

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Air Traffic Control Crisis Intensifies, With Ramifications for Avionics Industry

Global Avionics Round-Up from Aircraft Value News (AVN)

Phoenix Sky Harbor’s Air Traffic Control Tower and TRACON (Photo: Jacobs)

The U.S. aviation system continues to grapple with a deepening Air Traffic Control (ATC) crisis, as staffing shortages, outdated technology, and operational inefficiencies converge, raising concerns about safety and efficiency in the National Airspace System (NAS).

The U.S. Federal Aviation Administration (FAA) is confronting a significant shortfall of approximately 3,000 air traffic controllers, with over 90% of U.S. control towers operating understaffed. Despite recent efforts to recruit and train new personnel, including partnerships with educational institutions such as Nashua Community College in New Hampshire, the agency faces challenges in meeting its hiring targets.

Compounding the issue, recent changes to the Air Traffic Skills Assessment (ATSA) exam have led to a higher attrition rate among trainees. Under former Transportation Secretary Pete Buttigieg, the FAA lowered the threshold for the “best-qualified” category from 85% to 80%, resulting in a 30% increase in washout rates. Current Secretary Sean Duffy has reinstated a stricter grading system to expedite the entry of top candidates into the FAA Academy.

Technological Overhaul: NOTAM Modernization and TFDM Deployment

In response to systemic failures, the FAA is accelerating efforts to modernize critical technologies. The Notice to Air Missions (NOTAM) system, a vital component for flight safety, is undergoing a significant upgrade. A new cloud-based system, developed by CGI Federal, is slated for deployment by September 2025. This modernization aims to reduce outdated and redundant notices, enhancing the efficiency of flight operations.

Concurrently, the Terminal Flight Data Manager (TFDM) program is being expanded to improve surface operations at airports. TFDM replaces paper-based flight strips with electronic systems, streamlining communication between air traffic controllers and pilots. However, the rollout has faced delays, with cost increases and reduced deployment sites affecting its full implementation.

Operational Challenges and Safety Concerns

Recent incidents have highlighted the vulnerabilities in the current ATC system. A deadly mid-air collision near Washington, D.C., in January 2025, underscored the risks associated with controller shortages and procedural lapses. Investigations revealed preventable errors and regulatory failures, leading to calls for stricter safety regulations.

At Newark Liberty International Airport, ongoing staffing issues have led to repeated flight reductions. The FAA has implemented measures to ease congestion, but these actions have been met with mixed reactions from the aviation industry.

Industry Response and Legislative Actions

The aviation industry is intensifying its lobbying efforts to secure federal investment for ATC modernization. Airlines for America, now led by former New Hampshire Governor Chris Sununu, is advocating for substantial funding to address staffing shortages and technological deficiencies.

In response to these challenges, Congress has approved $12.5 billion in reform funding, with an additional $19 billion pending. These funds are earmarked for workforce development, technological upgrades, and infrastructure improvements to enhance the resilience of the NAS.

Implications for Avionics and Flight Operations

The ATC crisis has significant implications for avionics and flight operations. Pilots and operators are experiencing increased workloads due to controller shortages and procedural changes. The modernization of the NOTAM system and the implementation of TFDM are expected to alleviate some of these pressures by providing more accurate and timely information.

However, the success of these technological upgrades hinges on their integration with existing avionics systems. Manufacturers and operators must ensure compatibility and readiness to fully leverage the benefits of these advancements.

Looking Ahead

The FAA’s efforts to address the ATC crisis are multifaceted, involving staffing enhancements, technological modernization, and operational reforms. While progress is being made, the path to a fully resilient and efficient ATC system remains challenging. Continued collaboration among the FAA, the aviation industry, and legislative bodies will be crucial in shaping the future of U.S. air traffic control.

This article originally appeared in Aircraft Value News.

John Persinos is the editor-in-chief of Aircraft Value News.

The post Air Traffic Control Crisis Intensifies, With Ramifications for Avionics Industry appeared first on Avionics International.

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RTX’s Pratt & Whitney Receives $2.8 Billion for Lot 18 of F135

Pratt & Whitney’s F-135 engine, pictured here on the final assembly line. Photo, courtesy of Pratt & Whitney.

RTX‘s Pratt & Whitney has received a $2.8 billion U.S. Navy contract for Lot 18 F135 engines for the three variants of the Lockheed Martin F-35 Lightning II fighter.

The contract includes production and spare engines for DoD and foreign nations’ militaries, spare modules, program management, tooling, engineering and production support, Pratt & Whitney said.

“The F135 program sustains more than 67,000 domestic jobs, 240 U.S. suppliers and contributed more than $9.1 billion to the U.S. economy in 2024,” according to the company. “To date, Pratt & Whitney has delivered more than 1,300 F135 production engines to a global enterprise that includes 20 allied nations.”

Carrying over a provision since 2024, House and Senate appropriators’ versions of their fiscal 2026 defense bills bar DoD from funding an F-35 alternative engine to the F135.

The Senate appropriators’ bill adds $280 million for F135 spares and $500 million for F-35 sustainment to help address “sub-optimal projected operational readiness rates.”

On Sept. 30 last year, DoD said that Pratt & Whitney had received a received a more than $1.3 billion cost plus incentive fee contract for the F135 Engine Core Upgrade (ECU).

In fiscal 2024, the Air Force decided to scrap the Advanced Engine Transition Program and move ahead with ECU.

A version of this story originally appeared in affiliate publication Defense Daily.

The post RTX’s Pratt & Whitney Receives $2.8 Billion for Lot 18 of F135 appeared first on Avionics International.

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Hundreds Of Switchblades Delivered So Far In First Replicator Tranche, DIU Official Says

AeroVironment’s Switchblade 600 loitering munition. Photo: AeroVironment

AeroVironment’s Switchblade 600 loitering munition. Photo: AeroVironment

AeroVironment’s Switchblade 600 loitering munition. Photo: AeroVironment

The contractor supplying Switchblade loitering munitions to the Defense Department under the first phase of the Replicator initiative has delivered “hundreds” of systems to a customer who has fielded them, a Defense Innovation Unit (DIU) official said on August 28.

Deliveries of the AeroVironment-built Switchblade drone munitions have demonstrated the success of Replicator 1, Sarah Pearson, director of commercial engagement for DIU, said during a panel discussion at the NDIA Emerging Technologies conference.

Pearson declined to disclose the customer but the Army last year said it would buy and field more than a 1,000 AV Switchblade 600s over the next year under Replicator. The “hundreds” delivered so far that Pearson mentioned is the first time DoD has put a number on the Switchblades delivered under Replicator.

“We consider the problem set to have been met,” Pearson told reporters after the panel. “We were able to field hundreds, not multiple 1,000s, sticking with hundreds. We are transitioning the capability and one of our smartest lines with it to a specific service to start. And so, from a DIU perspective it was a prototype effort. We are now transitioning.”

Last week, T.S. Allen, DIU’s former director for Replicator 1, said when he left DIU “a couple of months ago,” the unit had delivered “hundreds of drones to warfighters, not just getting them to some exercise in Indiana but actually getting them out to the joint force, which was really exciting.”

Speaking during panel hosted by the Brookings Institution, Allen said, “We put thousands more on contract and when I left, they were still rolling off the assembly line. So, I count that as a win, and sort of, mission accomplished.”

Last December, Wahid Nawabi, AV’s chairman, president, and CEO, said on a company earnings call that it had begun Switchblade 600 deliveries for Replicator, highlighting that AV is the “poster child of that entire initiative.”

Then Deputy Defense Secretary Kathleen Hicks announced the Replicator initiative in August 2023, with a goal to acquire and field thousands of affordable all-domain, attritable autonomous unmanned systems by August 2025 to counter China in the Indo-Pacific theater (Defense Daily, Aug. 28, 2023). Since then, DoD has said Anduril Industries Altius-600 loitering munition and Ghost-X unmanned aircraft system (UAS) are part of Replicator, along with the Performance Drone Works C-100 UAS, and other low-cost long-range strike capabilities and maritime uncrewed systems that are classified.

DIU last November also announced software awards to seven companies for command and control, and autonomous collaborative teaming under Replicator.

Pearson said Replicator has demonstrated that once a “clear demand signal” is set, manufacturing timelines for the systems of interest can be reduced, and vendors can surge production capacity.

“Replicator is a perfect use case,” she said. “We said exactly how much and people said they could surge.”

Another benefit of the Replicator effort has been the test and evaluation piece, Pearson told the audience. With autonomous systems, “you learn through failure,” and that learning is happening, resulting in fixes. It’s better to have these systems “collide” with one another than having a person “pay the price,” she said.

“So, as long as we can train and continue retraining models and devices instead of people, that’s a win,” she said. “And Replicator helped us establish that.”

A version of this story originally appeared in affiliate publication Defense Daily.

The post Hundreds Of Switchblades Delivered So Far In First Replicator Tranche, DIU Official Says appeared first on Avionics International.

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General Atomics YFQ-42A First CCA Forerunner to Fly

A YFQ-42A Collaborative Combat Aircraft lands after a test flight in California on Wednesday (U.S. Air Force Photo)

A YFQ-42A Collaborative Combat Aircraft lands after a test flight in California on Wednesday (U.S. Air Force Photo)

A YFQ-42A Collaborative Combat Aircraft lands after a test flight in California on Wednesday (U.S. Air Force Photo)

A General Atomics Aeronautical Systems Inc. (GA-ASI) YFQ-42A Gambit prototype for the U.S. Air Force’s Collaborative Combat Aircraft (CCA) program flew for the first time in California on Wednesday ahead of what the Air Force expects to be a CCA Increment 1 downselect in fiscal 2026, which starts Oct. 1.

The Air Force has also said that it expects to start the development of CCA Increment 2 next year.

For Increment 1, the YFQ-42A is competing against a Anduril Industries YFQ-44A Fury prototype, which has not yet flown. Anduril said on August 27 that the YFQ-44A will fly soon.

“The CCA went from concept to flight in just 16 months after the contract was awarded–proving that we can deliver combat capability at speed,” Air Force Secretary Troy Meink said in a statement on August 27.

To accelerate CCA fielding, the Air Force said that it “is executing a multi-faceted learning campaign.”

“This includes rigorous vendor-led developmental testing, independent evaluations at Edwards AFB, Calif., and operational assessments by the Experimental Operations Unit at Nellis AFB, Nev.,” the service said.

“YFQ-42’s autonomy core has been trained across more than five years of flight testing using GA-ASI’s jet powered MQ-20 Avenger,” according to General Atomics. “The integrated capabilities of a stealthy, air-to-air focused uncrewed jet, combined with a learned AI autonomy core, provide warfighters with a definitive advantage in the future fight.”

In April last year, the Air Force narrowed the CCA Increment 1 field to General Atomics and Anduril.

The range of the U.S. Air Force’s prototype CCAs are to be at least 700 nautical miles–greater than the 590 nautical mile range of the Air Force F-22 Raptor fighter by Lockheed Martin and the 670 nautical mile range of the service’s F-35A Lightning II, also by Lockheed Martin.

Beale AFB, Calif.–the home of the U-2 surveillance plane–is to house the Aircraft Readiness Unit for CCAs to allow them to deploy quickly.

The House Armed Services Committee wants the U.S. Air Force to lay out its plan for full- scale production of CCA Increment 1.

A version of this story originally appeared in affiliate publication Defense Daily.

The post General Atomics YFQ-42A First CCA Forerunner to Fly appeared first on Avionics International.

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USAF Expects to Field BTAR Fix for KC-46A Late in Fiscal 2027

A Boeing KC-46A refuels a U.S. Air Force F-15 midair. (Photo: Boeing)

A Boeing KC-46A refuels a U.S. Air Force F-15 midair. (Photo: Boeing)

A Boeing KC-46A refuels a U.S. Air Force F-15 midair. (Photo: Boeing)

The U.S. Air Force expects to field a fix for the stiff aerial refueling boom (ARB) on the Boeing KC-46A Pegasus tanker late in fiscal 2027.

“The stiff boom deficiency is being resolved via the boom telescopic actuator redesign (BTAR) effort currently expected to field in late fiscal year 2027,” Air Force Life Cycle Management Center (AFLCMC) at Wright-Patterson AFB, Ohio said in an email response to questions on August 29.

The BTAR is expected to help avoid accidents that have resulted from “nozzle binding” on F-15E and F-22 Raptor fighters.

While the Air Force has cited the stiff ARB as an issue for the slower A-10 close air support aircraft, the stiffness has also been a problem for pilots of faster fighters, such as the Boeing F-15E Strike Eagle and Lockheed Martin F-22, and KC-46A boom operators have had problems with remote operation of the boom.

Such conclusions come from three Accident Investigation Board (AIB) reports Air Mobility Command (AMC) at Scott AFB, Ill., released on Aug. 25 regarding KC-46 accidents on Oct. 15, 2022; Nov. 7, 2022; and Aug. 21 last year.

The first involved a KC-46A from the 305th Air Mobility Wing at Joint Base McGuire-Dix-Lakehurst, N.J., and a “nozzle binding event” during which the plane’s ARB struck the aircraft’s tail section and caused more than $8.3 million in damage during a refueling attempt near Newfoundland of an F-15E Strike Eagle with the 335th Fighter Squadron at Seymour Johnson AFB, N.C.

A KC-46A from the 305th Mobility Wing had a similar “nozzle binding” with a 1st Fighter Wing F-22 Raptor fighter during a refueling off the coast of Florida on Nov. 7, 2022–a binding that caused the loss of the more than $103,000 nozzle.

In the third accident on Aug. 21 last year, a KC-46A with the 22nd Air Refueling Wing at McConnell AFB, Kan., had a “nozzle binding” over Switzerland while trying to refuel an F-15E from the 366th Fighter Wing at Mountain Home AFB, Idaho, and AIB assessed the resulting damage to be $14.4 million.

AIB said that “there is minimal discussion, if any, of the boom logic functions in the Flight Crew Operating Manual, the KC-46 Boom academics, or the [Air Force Tactics, Techniques, and Procedures publication] 3-3.b KC-46.”

“The only reference to fault detection out-of-range limit rates, ‘return to home’ function, and boom envelope soft limits were found in manufacturer proprietary and independent technical evaluation data specifically analyzed as a result of this mishap,” according to the AIB report. “There is currently a deficiency in the depth of boom system logic and boom flight control systems knowledge in KC-46 baseline manuals and academics. Additionally, many initial cadre flight instructors for the KC-46 were prior boom operators on the KC-135, which did not have any automated boom flight control systems. The tactics, techniques, and procedures for alleviating nozzle binding and ‘flying the boom’ in the KC-135 are contraindicated for the KC-46 automated systems and may have contributed to outdated techniques being taught during training.”

AMC first identified the KC-46A stiff boom as a Category I deficiency in a Sept. 10, 2018 report entitled Boom Telescope Too Stiff While In Contact With Receiver. In May, Air Force Chief of Staff Gen. Dave Allvin told the House Appropriations Committee’s defense panel that the KC-46A still has five unresolved Category 1 deficiencies–the stiff boom, two Category I deficiencies on the Remote Vision System, one on the mast drain, and one on the environmental control system.

“‘Nozzle binding’ is not uncommon during boom refueling and is a known issue for the KC-46 that when compounded with other factors can result in incidents like those associated with the AIBs,” AFLCMC said in the email answers on August 29. “‘Nozzle binding’ is generally not identified or recorded unless it results in such incidents.”

A version of this story originally appeared in affiliate publication Defense Daily.

The post USAF Expects to Field BTAR Fix for KC-46A Late in Fiscal 2027 appeared first on Avionics International.

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Rewired: How Boeing Is Rethinking MAX Avionics for a Safer Future

Global Avionics Round-Up from Aircraft Value News (AVN)

Boeing 737 MAX cockpit. (Boeing)

After years of crisis, lawsuits, and soul-searching, Boeing is under pressure like never before to rebuild trust in the 737 MAX. While much of the focus has been on mechanical fixes and quality control, one of the most significant transformations is happening inside the flight deck.

Boeing is quietly rolling out a wave of avionics improvements to the MAX family, not just to meet regulatory demands, but to restore confidence and enhance long-term safety.

The post-grounding MAX 8 and MAX 9 already include updates to the flight control software and redundancy protocols. But Boeing is going further, working with Collins Aerospace to refine the underlying avionics architecture.

One major change initiated by Boeing is a shift toward more robust fault detection and isolation systems. These digital watchdogs monitor sensor inputs and cross-check data in real time, ensuring that a single erroneous reading, like the one that triggered MCAS in the past, can’t bring down the entire system.

Another area of improvement is display integration. The MAX flight deck retains six large LCD screens, but Boeing has refined the user interface and alarm hierarchy to prioritize clarity and minimize cognitive overload.

Pilots now receive more context-rich alerts, with better differentiation between advisory, caution, and warning levels. These changes are rooted in human factors research aimed at preventing task saturation during high-stress moments.

Boeing is also enhancing the MAX’s data-sharing capabilities. The latest models feature upgraded data links that allow for real-time health monitoring and position reporting. Airlines can now tap into predictive maintenance tools that flag potential failures before they happen, improving both safety and fleet efficiency. These systems are tied into Boeing’s Airplane Health Management (AHM) platform, which aggregates data across an operator’s fleet for faster decision-making.

Enhanced cybersecurity…

Cybersecurity has also moved to the front burner. With increasingly connected cockpits, Boeing is embedding hardened encryption protocols and multi-layered access controls to protect against unauthorized intrusion. As digital threats grow more sophisticated, avionics must be designed with a zero-trust architecture mindset, and Boeing has begun to incorporate those principles into MAX systems.

The most meaningful change, however, may be philosophical. Boeing is moving away from a culture that once prized design minimalism and pilot continuity above all else. That mindset contributed to the MCAS debacle. Today’s MAX upgrades reflect a more balanced approach: respecting pilot experience while embracing automation that informs, rather than overrides.

Boeing’s rival Airbus has long led in cockpit integration and automation philosophy. With these avionics enhancements, Boeing is signaling that it’s ready to match that standard, technically as well as culturally.

None of these upgrades erase the scars of the MAX crisis, but they point to a company trying to relearn the value of thoughtful systems design.

This article originally appeared in our partner publication Aircraft Value News.

John Persinos is the editor-in-chief of Aircraft Value News.

The post Rewired: How Boeing Is Rethinking MAX Avionics for a Safer Future appeared first on Avionics International.

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Neo Brains: How Airbus Is Future-Proofing the A320 Cockpit

Global Avionics Round-Up from Aircraft Value News (AVN)

 

Airbus has long been known for its forward-thinking approach to avionics, and nowhere is that more evident than in the A320neo family. Introduced in 2016, the “neo” — for “new engine option” — wasn’t just a fuel-efficiency upgrade. It was an avionics statement, integrating the latest digital tools to reduce pilot workload, improve situational awareness, and boost operational flexibility.

At the heart of the A320neo’s avionics suite is the integrated modular avionics (IMA) architecture, built in partnership with Thales. It consolidates multiple computing functions, e.g. flight control, navigation, and communication, into fewer processing units, reducing wiring, weight, and system complexity.

This approach makes for easier maintenance, faster updates, and a common digital backbone across aircraft variants. The result is a cockpit environment that feels more like a smart workstation than a traditional airplane flight deck.

What sets the A320neo apart isn’t just the integration, but the way Airbus has embedded predictive capabilities into the avionics. The aircraft’s Flight Operations and Maintenance Exchanger (FOMAX) system collects and transmits over 24,000 parameters in real time, enabling airlines to perform condition-based maintenance and make smarter fleet-wide decisions. That kind of connectivity is critical in a world where ground time is money and reliability is king.

Airbus is also rolling out enhancements to the cockpit displays and Flight Management System (FMS), with touchscreen interfaces and improved data visualization. These upgrades are designed to be backward-compatible with existing A320neo airframes, giving operators the ability to modernize without major overhauls.

The company’s long-term vision includes tighter integration with air traffic management networks, allowing the aircraft to negotiate optimal trajectories and dynamic reroutes with ground systems, a necessity as airspace congestion grows.

A holistic digital cockpit…

So how does Boeing stack up? On paper, the 737 MAX family includes many of the same building blocks: a modern FMS, large-format displays, and satellite-based navigation.

However, the MAX retains legacy architecture rooted in the original 1960s-era 737 design. Its avionics, provided primarily by Rockwell Collins (now Collins Aerospace), are very capable but not as upgrade friendly as Airbus’s IMA platform.

That’s partly by design. Boeing prioritized commonality with earlier 737s to simplify pilot training and certification, especially in fast-growing markets. But that tradeoff has come under scrutiny following the MCAS-related crashes, where deeper integration and situational transparency might have prevented tragedy. Airbus, in contrast, has invested in a more holistic digital cockpit, where automation supports, but doesn’t obscure, the pilot’s role.

Airbus is now preparing for a “neo-plus” evolution, with next-gen flight deck concepts, more AI-based support tools, and tighter integration with urban air mobility ecosystems. The goal is to future-proof the aircraft’s role in a rapidly changing airspace environment, from drone corridors to hybrid-electric propulsion.

This article originally appeared in our partner publication Aircraft Value News.

John Persinos is the editor-in-chief of Aircraft Value News.

The post Neo Brains: How Airbus Is Future-Proofing the A320 Cockpit appeared first on Avionics International.

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