Unmanned Combat Aerial Vehicle (UCAV) Airframe assembly design and engineering

Background

The CATS Warrior, a flagship initiative by Hindustan Aeronautics Limited (HAL), is set to revolutionize aerial combat. Designed as a loyal wingman within the Combat Air Teaming system (CATS), the CATS Warrior seamlessly collaborates with the LCA mothership, taking on high-risk missions such as strike, surveillance, reconnaissance, electronic warfare, decoy operations, and swarm attacks. Its advanced Autonomous Take-off and Landing (ATOL) capabilities, combined with a low-observable profile, make it an invaluable asset for complex combat environments, reducing the risk to human pilots.​

Tata Elxsi proudly partnered with HAL in this groundbreaking venture, contributing to the design, engineering, and fabrication of the airframe assembly, fuel storage system, and landing gear for the full-scale CATS Warrior demonstrator. By combining our aerospace engineering expertise with HAL's deep aviation legacy, we developed a solution that not only met but exceeded the performance criteria, helping create a full-scale demonstrator in record time eventually lead in compressed timelines of the actual product development.​

Challenge

The CATS Warrior project came with a tight 14-week deadline, demanding precision in every phase. The team had to ensure dimensional accuracy, symmetry, weight target and a leakproof fuel storage system, all while navigating complex air duct fabrication.

On top of these engineering hurdles, the demonstrator had to endure engine ground runs and taxi trials to ensure real-world readiness. With Aero India 2025 on the horizon, the project had to meet stringent aerospace standards and exceed global expectations.

Solution

With the clock ticking and challenges mounting, Tata Elxsi embraced a structured, multi-phase approach to bring the CATS Warrior demonstrator to life. We began with a thorough material selection process, followed by hand calculations and stress analysis to ensure the UCAV met both weight and performance criteria. With precision, our team then moved on to the preliminary and detailed design of the airframe, integrating over 1200 components, followed by the meticulous fabrication of the airframe and fuel storage system to meet every design parameter.

Once the Airframe was ready extensive testing was carried out to validate key metrics such as structural integrity, weight distribution, center of gravity (CG), symmetry, and fuel system integrity. Following successful validation, we integrated landing gear, light control systems, avionics and the demonstrator underwent engine ground runs, confirming its readiness for the next stage of testing and validation, and paving the way for its public demonstration at Aero India 2025.

Impact

Tata Elxsi’s contribution to the CATS Warrior project not only ensured the successful completion within the aggressive 14-week timeline but also exemplified engineering precision and seamless system integration. The demonstrator met every critical design requirement, from dimensional accuracy to symmetry and weight targets. Our team engineered over 1,200 airframe components, 60 landing gear components, and 28 electrical components, each crafted to meet its expected performance.

The successful completion of engine ground runs further validated its operational readiness, confirming the demonstrator’s performance capabilities. The CATS Warrior demonstrator was proudly unveiled at Aero India 2025, where it garnered global recognition for its cutting-edge design and unmatched operational capabilities, cementing its place as a game-changer in aerial combat technology

Where are we now

The CATS Warrior is approaching its first flight by 2026, following extensive ground testing and upcoming low-speed taxi trials. Having delivered the demonstrator, Tata elxsi has been entrusted with the task of design, development and installation of fuselage assembly jigs for the flying prototypes of CATS Warrior.

Services Rendered

• Material selection and preliminary design
• Stress analysis
• Airframe detailed design and development
• Assembly jig design and development
• Demonstrator development
• Testing and validation
• System integration