The UK’s first supersonic combat aircraft project in four decades is moving from concept to reality. BAE Systems’ Lancashire facilities are now manufacturing two-thirds of the Combat Air Flying Demonstrator‘s structural weight, using digital techniques that mark a radical departure from traditional aerospace production.
This demonstrator, set for first flight by 2027, will test technologies for the Global Combat Air Programme (GCAP) fighter – a UK-Japan-Italy partnership targeting service entry by 2035.
“This project delivers the UK’s first crewed combat demonstrator in four decades… building technical foundations, workforce readiness, and digital maturity for GCAP,” said Tony Godbold from BAE Systems.
Digital Manufacturing Revolution
At BAE’s Lancashire sites, the demonstrator’s fuselage, wings and tail components emerge through 3D printing, robotic assembly, and “cobotics” – collaborative human-machine teams working side by side.
Digital twins allow engineers to test components virtually before production. This approach has enabled RAF, BAE and Rolls-Royce pilots to log over 300 simulator hours, validating flight control systems long before actual takeoff.
Technical Profile
The aircraft features a delta-wing design with blended fuselage-wing integration and stealth-compatible intake designs to reduce radar detection. Twin canted tail fins further contribute to its low-observable characteristics.
The demonstrator is 3-4 meters longer than the Eurofighter Typhoon, suggesting increased range. Its wide nosecone is large enough to accommodate advanced sensor systems, while radar capabilities are being developed under the UK-Japan JAGUAR programme between Leonardo UK and Mitsubishi Electric.
The demonstrator’s propulsion system will test next-generation engine technologies, including Rolls-Royce’s adaptive-cycle designs that will provide ten times more electrical power than current Typhoon fighters, enabling future AI and directed-energy weapons systems.
Similar Posts:
Industrial Ecosystem
“The demonstrator provides invaluable lessons for future combat air delivery, equipping our people with skills for GCAP,” noted Richard Berthon from the UK Ministry of Defence.
This skills pipeline includes 1,000+ apprentices and graduates recruited since 2018. The program supports over 3,500 personnel as part of Team Tempest, with more than 600 suppliers contributing, including 91 small and medium enterprises.
Sustainability is embedded in the digital manufacturing process, reducing material waste by 30% compared to traditional methods. The digital approach allows for rapid design iterations and testing without the need for physical prototypes.
International Framework
The GCAP effort formalized its structure with headquarters established in Reading, UK in mid-2025. Each partner nation – the UK, Italy and Japan – holds equal 33.3% stake in “Edgewing,” the joint program entity established in June 2025.
The collaboration builds on the UK’s Tempest program (launched 2018) merging with Japan’s F-X project, with Italy joining in 2019. A development treaty signed December 2023 provides the legal foundation for joint R&D activities. BAE’s Herman Claesen has confirmed that while Saudi Arabia is unlikely to join GCAP due to program momentum, several other nations have expressed interest in future collaboration.
The demonstrator features a cropped delta-wing design, while the final GCAP fighter will utilize a larger true delta-wing for enhanced range and speed performance.
With assembly now progressing, the program remains on schedule for first flight by 2027 and operational fighter delivery by 2035. The demonstrator connects historic British aerospace expertise with modern digital manufacturing, ensuring sovereign combat air capabilities continue to develop within the national industrial base.
