HAL has struggled to meet production targets, delaying the introduction of operational aircraft.
Hindustan Aeronautics Limited (HAL) Tejas Mark 1A, a light combat aircraft, takes off before its maiden flight at HAL Nashik, India, on October 17, 2025. PHOTO: Reuters
ISLAMABAD:
The crash of the indigenous Tejas light fighter jet, developed by India’s Hindustan Aeronautics Limited (HAL) and the Defense Research and Development Organization (DRDO), has raised serious concerns over the fighter jet’s operational readiness, safety standards and long-standing technical difficulties.
The crash, which occurred during a public aerobatic display at the Dubai Airshow, has prompted aviation experts and military analysts to weigh in on the series of systemic failures that have plagued the Tejas program for decades. Although the exact cause is still under investigation, experts suggest that a combination of technical glitches, systemic problems in development, and operational pressures may have played a critical role in the accident.
Aviation experts point to a history of development delays, chronic quality control issues, engine integration difficulties and a general dissatisfaction by the Indian Air Force (IAF) with the aircraft’s performance. These problems, over time, have resulted in a warplane that has struggled to meet both internal expectations and external demands.
The Tejas program, which began in the 1980s, was touted as India’s flagship indigenous fighter, a symbol of the country’s self-reliance in combat aviation. However, nearly four decades of development have been marred by delays and technical setbacks. The plane only came into operation in the last decade, and even then, it has been plagued with problems.
The latest in a series of worrying incidents was the crash of a Tejas fighter jet near Jaisalmer in the Indian state of Rajasthan on March 12, 2024, following an engine stall caused by a malfunctioning oil pump. Preliminary investigations indicated that this failure was a critical failure rather than pilot error.
The accident highlighted the vulnerability of the Tejas, a single-engine aircraft, to catastrophic failure when its propulsion system fails. It served as an early warning that the plane’s engine remained unreliable despite years of development.
According to aviation and aeronautics experts, the current problems with the Tejas engine are compounded by procurement and supply chain issues. Despite HAL’s efforts to integrate indigenous systems, the aircraft has been based on imported GE F404/F414 engines, which have suffered from delays in deliveries and occasional shortages of gearboxes and accessories.
These delays have forced the IAF and HAL to stagger production timelines, delay deliveries and scramble for workarounds, all of which have compressed testing schedules and created operational risks. All of these concerns were confirmed in the Dubai Airshow crash, leading aviation experts to draw connections between the failure in Jaisalmer and the more recent crash.
The Tejas was initially conceived as a multi-role fighter aircraft to replace the aging Russian MiG-21 fleet in the IAF. However, the program’s development path has not been easy. The timeline, spanning more than 40 years, has been plagued by shaky design requirements, technology gaps and the inability to freeze a final configuration for the aircraft.
Despite these problems, the Tejas continued to be displayed at international air shows as a symbol of India’s growing defense capabilities. However, the aircraft’s ability to meet the IAF’s stringent operational demands remains questionable as major issues remain in radar integration, defensive systems and combat survivability.
Another major factor contributing to the Tejas’ operational problems is the state of HAL’s manufacturing processes. Over the years, HAL has faced recurring quality control issues that have compromised the safety and reliability of the Tejas fleet.
HAL has struggled to meet production targets, delaying the introduction of operational aircraft. Despite the huge investment, HAL’s production capacity has been insufficient to meet the demand for Tejas aircraft within the IAF.
Reports of fluid leaks, panel misalignments, premature seal wear and grounding problems have dogged the Tejas fleet. These defects suggest flaws in HAL’s quality control processes and a failure to ensure that the aircraft meets basic operating standards before being delivered.
Meanwhile, HAL’s reliance on manual procedures rather than automated controls has contributed to human error during assembly and maintenance. The lack of automation in quality control has made it difficult to maintain high production standards, which is critical for military aircraft.
The Dubai accident exposed these deficiencies, as visible fluid leaks and other mechanical defects were evident before the flight. These defects should have been fixed during pre-flight inspections, but the rushed nature of the demonstration, combined with ongoing maintenance and quality control issues, led to a catastrophic mid-flight failure.
The Tejas was originally designed to be powered by the indigenous Kaveri engine. However, the failure of the Kaveri engine project forced HAL to resort to foreign engines, the GE F404/F414, which were not optimal for the airframe. This mismatch has resulted in several performance issues, including thrust limitations, aerodynamic disruptions, and increased maintenance complexity.
These performance limitations were particularly evident during the aerobatic display at the Dubai Airshow, where the Tejas was pushed to its limits, exacerbating any underlying problems with the engine or flight systems.
The Tejas uses a digital fly-by-wire system, a modern feature that should provide greater control and precision in flight. However, the system has faced significant instability issues since its introduction, including excessive sensitivity, software patches, and discrepancies between the pilot and autopilot.
Given the sensitivity of the Tejas’ flight control system and unresolved software issues, it is likely that the crash in Dubai was caused, in part, by a combination of these factors, making it difficult for the pilot to regain control during the high-stress aerobatic routine.
According to defense analysts, political pressure has also played a huge role in the trajectory of the Tejas program. As part of India’s “Aatmanirbhar Bharat” (Self-Reliant India) and “Make in India” initiatives, Tejas have become a symbol of national pride. However, this political pressure has often overshadowed technical concerns, leading to the aircraft being displayed at international air shows despite persistent problems with its design and performance.
They believe that the desire to project strength and technological prowess on the global stage has led to a situation where the aircraft was forced to perform demonstrations before it was fully operational, downplaying its technical deficiencies in favor of domestic optics. This approach, while improving India’s image, has clearly compromised the safety and performance of the Tejas.
Analysts say the Dubai accident is a reminder of deep-seated problems within India’s military-industrial complex. It underlines the importance of prioritizing technical readiness, quality control and security over political considerations in defense development.
The Tejas program, intended to be a symbol of India’s self-reliance, has instead become a case study in how repeated technical failures, compounded by political pressures and systemic inefficiencies, can lead to catastrophic results.
