India needs more passenger aircraft. Can it build them too?

India is one of the fastest growing aviation markets in the world.

IndiGo and Air India together hold more than 90% of the market and have ordered nearly 1,500 aircraft over the next decade, underscoring soaring passenger demand.

The expansion hinges on Boeing and Airbus, which together supply 86% of the world’s aircraft and face an “all-time high” delivery backlog in 2024 – with delays expected to impact Indian orders as well.

This revives an old question: Should India try to build its own passenger jet?

The prospect drew attention in October, when India and Russia signed a preliminary agreement in Moscow to build the SJ-100 passenger jet in India, raising hopes for domestic aircraft production.

But is the Russia deal the solution? Its joint manufacturing plans still face many obstacles before they can be realized.

The SJ-100 is a twin-engine aircraft that can carry up to 103 passengers and is already in service with several Russian airlines, according to its manufacturer, United Aircraft Corporation (UAC).

Delhi described the aircraft as a “game changer” and planned to use it on short-haul routes. But experts have questioned the project’s cost and feasibility, much of which remains unclear.

One of the biggest concerns is whether the Russian company will be able to quickly establish and scale up production in India.

The aircraft manufacturer said it delivered about 200 SJ-100 aircraft between 2008 and 2020. But this trajectory changed in 2022 when Russia launched a war against Ukraine.

Western sanctions have cut off key spare parts, forcing the company to replace about 40 systems and run “import substitution” versions in 2023. Europe’s aviation safety regulator withdrew the aircraft’s certification, effectively banning the SJ-100 and other Russian aircraft from its airspace.

India has long sought to build passenger jets domestically, but with only limited success.

In 1959, the government established the National Aerospace Laboratory (NAL) to develop “small and medium-sized civilian aircraft.”

The factory has developed two-seat Hansa and five-seat trainer aircraft, but larger airliners remain out of reach.

In the 1960s, India manufactured passenger aircraft under foreign license. State-run Hindustan Aeronautics Ltd (HAL) produced dozens of British-designed Avro 748 jets for use by commercial airlines and the military before being phased out.

In the 1980s, India cooperated with the German company Dornier to produce 19-seat passenger aircraft, some of which still serve military and limited civilian routes.

Along with this momentum, India is also trying to cleverly design its own small passenger aircraft.

In 2000, India also signed Agreement with Russia Seeking help in building NAL’s 15-seat Salas aircraft. The aircraft made its first flight in May 2004, but the project stalled in 2009 after an accident involving its second prototype killed three pilots.

A few years later, the Indian government revived the project and launched the next prototype, the Saras MK2, a 19-seat aircraft, which is still awaiting certification.

Another such program, the Regional Transport Aircraft (RTA), has also made little progress over the years. A feasibility report on a 90-seat aircraft comparable to the Russian SJ-100 was submitted in 2011, but little progress has been made since then.

Aviation experts say aircraft manufacturing in India has long faced obstacles.

NAL Director Dr Abhay Pashilkar noted that until recently, the “lack of substantial domestic demand” coupled with a shortage of highly skilled labor and a smaller domestic manufacturing ecosystem had hampered the industry’s growth.

The way out, he added, is “working with Indian and global manufacturers”.

So, is the SJ-100 project really a game changer?

So far it seems so.

Former HAL spokesperson Gopal Sutar said the plan provided a “pragmatic approach” as India’s own projects were far from complete.

For Moscow, widespread acceptance of the SJ-100 would also prove that they can build a civilian aircraft without Western technology.

While the deal comes with clear trade-offs and leaves questions about the future of India’s aerospace manufacturing ambitions, experts like Sutar believe Russia’s role as India’s “staunch supporter” remains crucial.

“Sanctions may create challenges, but both countries will take that into account,” he said.

Aircraft availability is only part of the challenge for Indian aviation; rapid expansion also depends on well-trained staff.

Earlier this month, IndiGo canceled thousands of flights due to “poor pilot roster planning”, leaving tens of thousands of passengers stranded for hours or even days.

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