TUSAŞ’s structural manufacturing capabilities are focused on the production of primary load-bearing structures, metallic and composite airframe components, and integrated system carriers for fighter aircraft, transport aircraft, and special mission platforms. These capabilities extend beyond manufacturing to include design authority, engineering change management, and lifecycle support.

Doctrine and Concept of Use

Modern aerospace programs increasingly rely on suppliers that act as design partners, not just manufacturers. TUSAŞ aligns with this doctrine by providing:

• End-to-end design and production support
• Structural modernization and improvement solutions
• Engineering services throughout the aircraft lifecycle

This approach significantly enhances platform sustainability and upgrade potential.

Platform Architecture and Integration

TUSAŞ produces:

• Metallic structures (aluminum and titanium alloys)
• Advanced composite structures (carbon fiber reinforced polymers)
• Hybrid structural assemblies

All components are designed for seamless integration with fuel systems, avionics, landing gear, external stores, and air intake systems while complying with OEM and NATO standards.

A400M Program – Transition to Design-to-Production

• A400M Atlas represents a major technological milestone for TUSAŞ.
• Transition from Drawing-to-Production to Design-to-Production
• Full design and procurement responsibility for:
  • Interior and exterior lighting systems (excluding cockpit)
  • Clean water and waste water systems
• Continuous design and engineering support throughout the aircraft’s service life

This role places TUSAŞ among a limited number of suppliers with genuine design authority within a major European military transport aircraft program.

JSF / F-35 Program – Strategic Global Contribution

F-35 Lightning II

Since 2008, TUSAŞ has provided high-quality, cost-competitive structural components to the JSF Program.

Key Responsibilities

• F-35A Center Fuselage
  • Produced by TUSAŞ as the only source outside the United States
• F-35A/B/C Composite Components
  • TUSAŞ is among the very limited number of global suppliers
• Other Major Structural Components
  • Metallic lower fuselage sections
  • Air intake assemblies
  • External air-to-ground stores pylons for F-35A/B/C variants

These components require extreme manufacturing precision, stealth-compatible surface quality, and strict adherence to structural and fatigue-life requirements.

Detailed Technical Capabilities

Dimensions and Weight

• Platform-specific primary structures
• Classified or not publicly disclosed exact dimensions and weights

Materials and Manufacturing Technologies

• Aluminum-lithium alloys
• Titanium structural components
• Carbon fiber composite structures
• Autoclave curing, AFP/ATL systems, high-precision CNC machining, advanced surface treatments

Performance and Precision

• Micron-level manufacturing tolerances
• High fatigue and damage tolerance
• Surface quality compatible with low observable (stealth) requirements

Integration and Compliance

• Full compliance with NATO and OEM quality standards
• Engineering and digital integration with
• Airbus and Lockheed Martin ecosystems
• Advanced PLM, configuration control, and digital manufacturing infrastructure

Production Sustainability

• Serial production-capable manufacturing lines
• Long-term contractual production capacity
• Lifecycle-oriented production and support philosophy

Frequently Asked Questions

Why is TUSAŞ a critical structural manufacturer?

• Because it holds design authority and long-term engineering responsibility, a capability granted to only a limited number of aerospace companies worldwide.

Why is the F-35 Center Fuselage so important?

• It is the main structural backbone of the aircraft, integrating wings, landing gear, engine mounts, and weapons stations.

Is TUSAŞ capable of stealth-compatible manufacturing?

• Yes. TUSAŞ has proven its ability to meet low observable surface and composite manufacturing standards through the F-35 Program.

What differentiates TUSAŞ in the A400M Program?

• TUSAŞ is not only a manufacturer but also the design owner of critical aircraft systems, providing engineering support throughout the aircraft’s lifecycle.

How do these capabilities support national programs?

• The accumulated expertise directly feeds into Türkiye’s indigenous programs such as KAAN and HÜRJET.

References

• TUSAŞ Official Publications and Corporate Releases
• Airbus A400M Program Documentation
• Lockheed Martin JSF/F-35 Program Briefings
• International aerospace and defense exhibition materials