SOURCE: RAUNAK KUNDE / NEWS BEAT / IDRW.ORG
In a significant development for India’s defence manufacturing ambitions, a senior official from Russia’s state-owned Rostec corporation has revealed that converting Hindustan Aeronautics Limited’s (HAL) Nashik plant into a production line for the Su-57E stealth fighter jet would require minimal new investment.
Speaking exclusively to idrw.org, the official highlighted that less than 30% of new tooling would be needed to refurbish the facility, thanks to the existing infrastructure, ground machinery, and equipment already in place from the production of Su-30MKI fighters for the Indian Air Force (IAF) over the past two decades.
The HAL Nashik plant has been a cornerstone of India’s defence aviation industry, primarily responsible for the licensed production of the Su-30MKI, a mainstay of the IAF’s fighter fleet. Since the early 2000s, the facility has produced nearly 200 Su-30MKIs under a technology transfer agreement with Russia’s Sukhoi Design Bureau, now part of the United Aircraft Corporation (UAC) under Rostec. This extensive production run has equipped the Nashik plant with specialized machinery, tooling, and skilled manpower capable of handling advanced fighter jet assembly.
According to the Rostec official, the plant retains much of the infrastructure originally used for the Su-30MKI program, including jigs, fixtures, and ground support equipment. While the Su-57E—a fifth-generation stealth fighter designed for export—incorporates advanced technologies like stealth shaping, composite materials, and next-generation avionics, its production process shares significant similarities with the Su-30MKI in terms of assembly techniques and manufacturing workflows. As a result, the official estimates that only 30% of the tooling would need to be replaced or upgraded to accommodate the Su-57E’s specific requirements, such as its stealth-oriented airframe and advanced subsystems.
The Rostec official emphasized that local production of the Su-57E at HAL Nashik would lead to substantial cost savings for India. “If India decides to locally manufacture them (Su-57), then it will cut down procurement costs as the money required for their manufacturing locally will be minimum, thus resulting in lower unit cost,” the official told idrw.org.
With much of the existing infrastructure already in place, the need for new investments in plant modernization would be limited. Refurbishing the Nashik facility would require significantly less capital than setting up a new production line from scratch.
Local production would allow India to negotiate better terms with Russia for raw materials, subsystems, and technology transfer, leveraging bulk procurement to drive down costs. Additionally, producing the aircraft in India would eliminate import duties and reduce transportation expenses associated with acquiring fully assembled jets.
The Nashik plant’s workforce is already experienced in assembling complex fighter jets, having honed their skills over two decades on the Su-30MKI program. This expertise would minimize training costs and accelerate the transition to Su-57E production.
While exact unit costs for the Su-57E remain undisclosed, analysts estimate that local production could reduce the per-unit price by 20-30% compared to direct imports, making the aircraft a more viable option for the IAF’s modernization plans.
Operationally, the Su-57E could significantly enhance the IAF’s capabilities, particularly in contested environments. Its stealth features would allow it to penetrate advanced air defences, while its supercruise capability—enabling sustained supersonic flight without afterburners—would provide a tactical edge in long-range missions. The aircraft’s ability to carry a wide range of weapons, including air-to-air missiles, precision-guided munitions, and hypersonic weapons like the Kinzhal missile, would make it a versatile platform for both defensive and offensive operations.
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