IAF Indigenises 97% of Frequently Used Fighter Spares, Saves ₹582 Crore in 5 Years

New Delhi: The Indian Air Force has localised 97 per cent of the spares it frequently uses for operational fighter aircraft, a development that has helped the service save ₹582 crore in foreign exchange over the past five years, officials have told CNN-News18. The figures point to a steady expansion of the IAF’s domestic maintenance ecosystem, with the Maintenance Command now having localised about 62,300 spares across a wide range of aircraft support requirements.

The indigenised items are not limited to niche components. They include everyday consumables and mission-critical equipment needed for routine flying operations, such as batteries, fighter aircraft tyres, pilot parachutes, power carts and escape-air explosives used in ejection seats. Many of these items were earlier sourced from foreign suppliers, leaving the service exposed to supply delays and external dependencies.

An official familiar with the effort said the progress has been driven by a mix of innovation and private-sector participation. “With innovativeness and private industry participation, 97 per cent of spares frequently required for operational units and 93 per cent of mandatory spares required for overhauling of decentralised fleets have been indigenised,” the official said.

What has been localised

Among the specific achievements highlighted by officials are 76 types of escape-air explosives for fighter ejection seats, 207 power carts, eight types of pilot parachutes and the hydraulic booster pump used in the Su-30MKI aircraft. Batteries and fighter tyres for multiple platforms have also been brought under domestic production or sourcing.

The 3D-printing facility set up by the IAF in 2022 has become an important part of this effort. It is being used to meet urgent and on-demand requirements, helping reduce the waiting time for critical replacements. The service is also working with private industry on innovation projects and on mass production of indigenised components, indicating that the localisation drive is intended to move beyond one-off fixes and into a more structured supply chain.

Domestic spending has also risen

The shift is visible not just in spares but also in capital procurement. Over the last two financial years, the IAF has recorded a 90 per cent share of domestic capital budget expenditure, a level that exceeds the mandate set by the Ministry of Defence. That suggests a wider preference for Indian industry in acquisitions, alongside the push to localise maintenance and overhaul support.

Why the push became urgent

The need to reduce dependence on overseas supply chains became more pressing because the IAF continues to operate a large number of foreign-origin platforms. These include Russian-origin Su-30MKI fighters, MiG-29s, Mi-17 helicopters and An-32 transport aircraft, as well as French-origin Mirage-2000 and Rafale fighters. All of these fleets require regular supplies of spares, aggregates, engines, avionics and specialist repair support to remain operational.

The Russia-Ukraine conflict exposed the vulnerability of relying on foreign suppliers, particularly for major aggregates such as aero-engines, critical avionics and specialist weapons that had to be sent abroad for repair and overhaul. In response, the IAF accelerated its life-extension programmes, expanded local repair and overhaul of Russian-origin systems and deepened partnerships with Indian companies as well as Russian firms to manufacture and overhaul spares in India.

Even so, the effort is not complete. In 2026, the service has still floated multiple procurement tenders for Su-30MKI spares, showing that full self-sufficiency across every category remains a work in progress. High-end areas such as aero-engines, advanced avionics and electronic warfare systems continue to pose challenges. But the localisation of frequently used and mandatory overhaul spares has already delivered measurable gains in fleet availability and cost savings.

Part of a longer self-reliance drive

The latest numbers build on earlier progress. In 2022, the then Air Officer Commanding-in-Chief of Maintenance Command had said the IAF had reached around 95 per cent self-reliance in daily spare requirements, with savings of roughly ₹600 crore over five years at that time. The current figures suggest that the service has not only sustained that momentum but also consolidated it further, especially in the area of operational fighter spares.

The effort also aligns with the government’s Positive Indigenisation Lists and the Sankalp-2026 compendium, which identifies specific problem statements for domestic industry related to Russian-origin platforms. Alongside these measures, the IAF has inducted indigenous systems such as the Akash missile and the SAMAR air defence system, adding another layer to the broader push for self-reliance in air defence and sustainment.

Impact on readiness and sustainment

For the IAF, the practical benefits are clear. Reducing dependence on foreign supply chains for high-turnover items improves aircraft availability, shortens maintenance turnaround times and helps insulate operations from geopolitical disruptions. The combination of private industry participation, in-house 3D printing and systematic localisation of both consumables and overhaul spares is strengthening the sustainment base for India’s combat fleet.

Officials say the work is continuing, with more items still to be localised and with deeper integration of Indian industry into the maintenance and repair ecosystem. But the saving of ₹582 crore in foreign exchange over five years, along with the 90 per cent domestic capital spend over the last two financial years, shows that the IAF’s self-reliance drive has moved from aspiration to measurable operational impact.