India’s drive for self-reliance in aerospace technology continues to gather pace but continues to get lusty blows from engine development aspect. One of the key milestones in this journey was the HAL HTFE-25 engine project. In development by Hindustan Aeronautics Limited (HAL), the HTFE-25 is a 25-kilonewton turbofan engine. HAL designed it to power single-engine jets, business aircraft, and unmanned aerial vehicles (UAVs) weighing up to five tonnes. In twin-engine configurations, it can support platforms up to nine tonnes. HAL sees a market potential of 200 to 250 units for this engine based on technical and operational feasibility.

HTFE-25 & Development Progress and Timeline

This engine’s development follows a two-stage process. HAL completed Stage I in December 2015, which covered project definition and basic design work. This stage was delayed from the original deadline of September 2014 and cost ₹52.87 crore. Stage II includes prototype development, testing, and final certification. It was originally due in September 2018, but remains incomplete as of July 2022. Several delays slowed progress significantly and increased the overall project cost.

Causes of Delay in HTFE 25

Delays in land clearance for test facilities were one major cause. HAL received land approval late due to long forest clearance procedures. Even after getting clearance, HAL took extra time to place construction orders for test beds. These combined delays added more than three years to the timeline. Meanwhile, HAL faced additional technical problems. Unplanned procurement activities and unexpected technology gaps further slowed development. The Intermediate Gear Box (IGB) became a critical bottleneck. HAL struggled to manufacture spiral bevel gears and also experienced vendor delays in supplying key components. These setbacks led to a cumulative impaired expense of ₹159.23 crore. The audit pointed to HAL’s lack of risk management and poor planning as major issues. The project continued to face delays due to missing contingency strategies and reactive decision-making.

R&D Commitment and Indigenous Push

Usually “HAL’s timeline overruns are overlooked considering lower R&D budget”. However, It spends around 9 percent of its turnover on R&D. This matches the R&D investment made by global aerospace firms like Boeing and Airbus. In the previous financial year, HAL invested ₹2,826 crore into research. The company also created a dedicated R&D corpus, allocating 15 percent of its profit after tax every year. This long-term investment ensures steady funding for future innovations. So, funding to the HTFE-25 project is ongoing and HAL’s effort to develop high-value gas turbine technologies should be recalibrated and refocused on delivery of projects in time bound manner.

Unique Challenges in Developing HTFE-25

Building a medium-thrust turbofan engine in India for the first time has been a huge challenge. HAL faced unexpected engineering problems and lacked domestic suppliers for niche technologies. This led to delays in test bed construction and engine component manufacturing. Delays in Intermediate Gear Box development and 3D technology adoption were particularly damaging. HAL had not included 3D design requirements at the start of the project. Risk mitigation strategies were introduced only later, which delayed course correction. Furthermore, the configuration had to be finalized through successful technology demonstrator (TD) testing before entering full development. These setbacks were not part of the original timeline and had to be addressed as they emerged.

A Vital but Delayed Mission

The HTFE-25 engine program is vital for India’s aerospace independence. It has experienced serious delays, yet it continues to move forward. HAL must now apply the lessons learned from past mistakes to avoid further slowdowns. Better planning, timely procurement, and stronger risk management will be critical in the next phase. The investment, though high, reflects India’s long-term commitment to defense indigenization. Once completed, the HTFE-25 could power a wide range of Indian platforms and reduce dependence on foreign engine suppliers. Despite the setbacks, this remains a mission worth pursuing.