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Exclusive: spotlight on F-35 production in Italy

In an enormous rectangular building in Cameri, Italy, a group of people swarms over the grey object that among them is known as AL-5. To others, it is known as the fifth Lockheed Martin F-35A Lightning II for the Italian Air Force. But judging by the language used, it’s not Italians who seem to turn AL-5 inside out. They are Americans, employed by Lockheed Martin and the US Department of Defense (DoD). And their job at hand is quality inspection of a factory fresh, Italian-made F-35 Lightning II.

An F-35A inflight. (Image © Lockheed Martin)
Related reading: F-35 takes a hit – from Canada. (Image © Lockheed Martin)

Airheadsfly.com’s recently paid a very exclusive visit to the rather secretive F-35’s Final Assembly and Check Out (FACO) facility in Cameri, which is run by Leonardo Aircraft and which rolled out its first F-35 in March 2015. The FACO is the result of extensive negotiations involving Italy, the US, Lockheed Martin and Leonardo Aircraft prior to 2010.

Development of the site started as soon as the ink was put on the contract. When epxloring the facility, it is hard to image that this 22-building, one million square feet complex was raised from the ground up in just three years. It is one of only three F-35 final assembly lines in the world, the others being Lockheed Martin’s production plant in Forth Worth, Texas, and Mitsubishi’s FACO in Nagoya, Japan.

Cameri sees final assembly of F-35A and B models for Italy, plus  F-35As for the Royal Netherlands Air Force (RNLAF) in the future. Other potential customers  may follow as well. “So far, we have completed delivery of four jets to the Italian Air Force, and we’re getting ready to hand over AL-5 as well. The first four were flown to the US for pilot training, but the fifth will stay in Italy. It will be delivered to the 32nd Stormo (wing) at Amendola airbase soon”, says brigadier-general Giuseppe Lupoli, F-35 FACO program manager on behalf of the Italian Ministry of Defense.

(Image © Airheadsfly.com)
Work in progress on an F-35A for the Italian Air Force. Visible in the background is the first F-35B to be produced in Cameri. (Image © Airheadsfly.com)
An F-35A takes shape in one of 11 assembly docks in the Cameri FACO. (Image © Airheadsfly.com)
An F-35A takes shape in one of 11 assembly docks in the Cameri FACO. (Image © Airheadsfly.com)

Assembly

Situated in the center of the FACO is the assembly hall. It covers eleven assembly bays, in one of which Leonardo Aircraft employees now crawl under and over AL-8, the final aircraft of an initial order of eight F-35s from Italy. The same hall also covers five bays for future maintenace, repair and overhaul works on the Lightning II.

Whereas in Fort Worth the hugely expensive 5th generation fighter jets are manufactured on a moving production line, in Cameri an F-35 stays in a specific assembly bay for the whole build process, with parts being brought to the jet. “Our bay approach is certified by Lockheed Martin and elements of it have even been introduced in Fort Worth”, says Lupoli. At full speed, the Cameri FACO is said to be capable of delivering two new jets per month.

The first F-35 Lightning II from the assembly line in Italy (Image © Larry Bramblett / Lockheed Martin)
The first Cameri-built F-35 Lightning II was rolled out in March 2015.  (Image © Larry Bramblett / Lockheed Martin)

First F-35B

For now, production rate is not anywhere remotely near that. Most assembly bays remain unused and empty while awaiting a formal procurement decision from Rome. The exact numbers are debated for a considerable time already in Italy, but the country  currently is eyeing 52 more F-35As for its air force, plus 30 F-35B short takeoff/vertical landing (STOVL) variants to be used by both navy and air force.  Meanwhile, the FACO understandably needs to keep the production flow going. Lupoli: “Because of long lead times, we are indeed moving ahead with production of parts for the next batch of jets.” Indeed, during Airheadsfly.com’s visit the first Italian F-35B was seen in final assembly, along with more A-models for the air force.

Dutch jets

Also, 2019 will see production of the first F-35s for the Royal Netherlands Air Force. The RNLAF has for several years been performing operational test and evaluation (OT&E) with its first two Lightnings in the US and should initially see delivery of six more from Fort Worth. The remaining 29 out of 37 aircraft ordered are to be assembled in Cameri.

(Image © Airheadsfly.com)
In Cameri, F-35s also receive their stealthy coating. Here, a full scale mock up is used to test the FACO’s associated installation. (Image © Airheadsfly.com)

Quality

In the Netherlands some concerns were raised over the fact that a 90 million USD aircraft designed and ordered in the US, is to be manufactured in an Italian factory. Those concerns were mainly about quality control…. and that’s were those Americans swarming over AL-5 come in. Not one F-35 leaves this FACO without a US pilot test flying it and without personnel from both Lockheed Martin and US DoD performing an inspection that easily lasts a couple of days. Pieces of blue tape on AL-5’s stealthy coating mark the spots that apparently are not up to standard.

Although their number has been greatly reduced since production got underway, the presence of US personnel in Italy comes as no surprise given the sensitive nature of the F-35. Lupoli: “Even with an aircraft destined for the Italian Air Force, we first hand it over to US DoD personnel for inspection and acceptance. Only then does US DoD hand it back  to our own air force. By doing so, quality control here in Cameri is totally in line with the US standard.”

(Image © Airheadsfly.com)
US personnel inspects AL-5 before acceptance. Only then will US DoD hand the aircraft over to its customer, being the Italian Air Force. (Image © Airheadsfly.com)

Wings

Apart from complete jets, the FACO also produces full wing sets for use in Fort Worth, with a maximum capacity of 72 sets per year. Quality control is equally strict here. Experts check each wing before it is ‘closed’, which means the upper skin is joined with the lower skin, making components inside unreachable without extensive repair jobs. Recently, faulty insulation on piping inside the wing forced Lockheed Martin to do exactly that kind of work on dozens of F-35s. According to the Italians, the problem was not found on Cameri-made wings.

The work done is testimony of the skills acquired by Leonardo Aircraft employees in just a few years’ time. In total, F-35 works in Cameri should generate an estimated 6,000 Italian jobs and add 15.8 billion USD to the Italian economy.

Lifespan
The Cameri site is projected to be in operation for at least forty years, during which focus will shift more and more to maintance, repair and overhaul of European. Lupoli: “Over the next 15 years, we expect to reduce the number of assembly bays and turn those into additional bays for F-35 maintenance.”

That’s no surpise, given the fact that Cameri back in 2014 was appointed as  the sole provider of heavy F-35 airframe maintenance in Europe. But to maintain one of the world’s most advanced and expensive military jets, this facility will first have to build them. To a passing visitor such as Airheadsfly.com, it seems the FACO is ready to fill those empty assembly bays and do exactly that. It seems ready to fulfill its projected contribution to the Italian economy as well as European defense needs. All it needs, are more actual F-35s to build.

© 2016 Airheadsfly.com editor Elmer van Hest
Featured image (top): A view of F-35 production in Cameri. (Image © Airheadsfly.com)

The first F-35A for the Italian Air Force takes off from Cameri FACO (Image © Todd McQueen, Lockheed Martin
The first F-35A for the Italian Air Force took off from Cameri  in September 2015. (Image © Todd McQueen, Lockheed Martin)

Mastering the Master

“Radar lock on Cobra 1”, I hear my pilot call from the front seat. And yes,  I can see it on the head up display (HUD) and on the screen between my knees. But the thing is, we don’t actually carry radar or air-to-air missiles. Seconds later and to my amazement, I see Cobra 1 in a thermal targeting image from a Litening pod on the left screen. The image reflects my actual view of Cobra 1 in our 1 o’clock position. But again, the thing is, we don’t actually carry a Litening pod. Welcome to the M-346 Master Advanced Jet Trainer and it’s world of simulation.

Click on the pictures for a larger image

Just 30 minutes before, Cobra 1 and Cobra 2 are both lined up at runway 14 at Lecce Galatina airbase in southern Italy. The military airfield houses the Italian Air Force’s 61st Wing and all seven M-346 Master Advanced Jet Trainers now in use. Two of those are now scheduled for a familiarization sortie in the area, with me in the backseat of Cobra 2. Flying Cobra 1 is the commander of 212 Gruppo, the squadron that since 2014 is the sole operator of the M-346 in the Italian Air Force.

(Image © Elmer van Hest)
Time for a selfie while holding short for take off. (Image © Elmer van Hest)

The flight follows after a visit to Leonardo Aircraft’s Venegono facility in northern Italy, where the remaining eleven Italian jets are still in production, next to a batch of eight aircraft for Poland. Leonardo puts the M-346 – called T-346A by the air force – on the market not merely as a Phase 4 Lead-in Fighter Trainer (LIFT) platform, but as an integrated training solution for military jet pilots, and one that makes good use of the virtues of simulation. In the costly world of 4th and 5th generation fighter jets, that’s not a bad place to start from.

Take off

Back in Lecce, we start our take off roll in formation and become airborne after only 15 seconds. Since I studied the Master’s cockpit the day before in Venegono, I already feel somewhat familair in these surroundings, but what catches me by surprise once in the air, is the nearly unlimited visibility from the back seat. I can observe nearly all of the world around me, but also what my pilot – whose tactical callsign is ‘Pants’  – is up to in the front seat. Pants is an instructor pilot (IP) and it’s his job to ready student pilots for the next step in their military flying career, which is flying 4th and 5th generation fighter aircraft such as the Typhoon, plus the F-35 Lightning II in the near future. But first, they’ll have to master the Master.

(Image © Elmer van Hest)
Rotation is achieved just 15 seconds or so after brake release. (Image © Elmer van Hest)
(Image © Elmer van Hest)
A topside view over Italian farmland. (Image © Elmer van Hest)
(Image © Elmer van Hest)
The sea turns turquoise while we execute a left hand turn. (Image © Elmer van Hest)

Data stream

In doing so, the 8 g capable M-346 should also be able to present student pilots with the same, endless data stream that fighter pilots are subjected to in combat situations. And after doing some pre-briefed photo set ups below and above the clouds first, the jet in fact proves it is capable of doing exactly that. Pants in quick succession shows me the various air-to-ground and air-to-air modes. If needed and by using the M-346’s embedded tactical simulation plus datalink capablities, an IP on the ground at Lecce could present us with an immediate tactical threat of any kind, and leave us to deal with it. It puts the right amount of pressure on any aspiring fighter pilot. But, thanks to Leonardo’s smart and unique Live Virtual Constructive (LVC), none of it is actually real.

(Image © Elmer van Hest)
Cobra 1 shows its belly to the camera. The small profile of the M-346 makes it quite hard to visually spot from distances. (Image © Elmer van Hest)
(Image © Elmer van Hest)
Barrell rolling in formation. (Image © Elmer van Hest)
(Image © Elmer van Hest)
And more aerobatics as seen from the backseat. (Image © Elmer van Hest)

Computer generated

The same goes for the thoroughly convincing thermal image I’m seeing of Cobra 1. That image is actually a computer generated picture, relayed to us via a ground station at Lecce. But to us in the cockpit of Cobra 2, it is like we are actually carrying a Litening pod beneath our aircraft.  I have to remind myself that in reality, we don’t. Our jet is in full trainer configuration, completely devoid of any external stores.

(Image © Elmer van Hest)
A climbing turn on the wing of Cobra 1. (Image © Elmer van Hest)
(Image © Elmer van Hest)
Cobra 1 in the distance… (Image © Elmer van Hest)
(Image © Elmer van Hest)
… and up close in a computer generated infrared image. (Image © Elmer van Hest)

Mean version

If it were up to Leonardo Aircraft back in Venegono, that may very well change. The company is currently developing the M-346FT (for Fighter Trainer), a weaponized variant of the M-346. ‘One system, one switch, two missions’, the head of Leonardo’s international sales division tirelessly repeats when talking about this ‘meaner’ M-346, that effortlessly turns from a trainer aircraft into a full fighter aircraft. Electronic warfare capabilities, chaff and flares, recce and targeting pods; all possibly turn from simulated to very real on the M-346FT.

The FT version was sparked by interest from Poland when ordering an initial batch of eight trainer versions. Deliveries of the first of these are set for November 2016. Leonardo is working on update kits that transform M-346 trainers into M-346FT warplanes.

Alternative

The M-346FT also is a noteworthy alternative to buying new expensive fighter jets for countries such as Argentina. That explains the visit to Lecce by Argentine Air Force pilots just a few days before my M-346 flight. Lecce is a melting pot of nationalities by any standards. The airbase houses student and instructor pilots not only from Italy, but also from Poland, Greece, Kuwait, Austria and Singapore among others.

(Image © Elmer van Hest)
Up, up, up! Despite not being equipped with afterburning engines, the M-346 has plenty of power. (Image © Elmer van Hest)
(Image © Elmer van Hest)
(Image © Elmer van Hest)

Dutch training

The Royal Netherlands Air Force (RNLAF) is also represented at Lecce. An instructor pilot has been flying the M-346 for about a year know, although the main objective of the Dutch delegation is to find out if fighter pilot training in Italy could replace current training in the US. Whereas Dutch student pilots were originally to fly the M-346 also, the RNLAF instead opted for the cheaper and less capable MB-339CD. The Dutch however are enthusiastic about the Italian way of training, and about the M-346 in particular.

Barrel rolls

Meanwhile, at 10,000 feet over the Mediterranean Sea, we do some tight turns, barrel rolls and more aerobatics in formation. By now, we have burned close to 1400 kilograms of fuel, so ‘bingo fuel’ is called and it’s time to head back to Lecce. Before we land, I take pictures of Cobra 1 overflying the airbase and the Ground Based Training System (GBTS) that reflects the increasing amount of simulator training that is being done at Lecce. Currently, 50 percent of flight training takes place in the simulator on the ground, but this percentage could grow to as much as 80 percent in the future, further driving down costs.

While Cobra 1 settles down on runway 14, Pants pushes forward the throttles for one more go around and a final circuit followed by a 130 kts landing. As we taxi back to the hangarettes and I switch my ejection seat to safe, I realize that I am truly impressed by the aircraft I have just spend 1 hour and ten minutes in. Mastering the Master appears quite a handful with all the information management tasks it is able to provide, but it’s exactly that which prepares students for what awaits them. It turns them from pilots into fighter pilots.

© 2016 Airheadsfly.com editor Elmer van Hest
Featured image (top): Breaking left! (Image © Elmer van Hest)

(Image © Elmer van Hest)
Over the coastal town of Santa Maria di Leuca…. (Image © Elmer van Hest)
(Image © Elmer van Hest)
… and over Lecce airbase, with the Ground Based Training System (GBTS) visible just to the right of the aircraft’s nose, plus the hangarettes in the lower right hand corner. (Image © Elmer van Hest)
(Image © Elmer van Hest)
Cobra 1 turning final for landing. (Image © Elmer van Hest)
(Image © Elmer van Hest)
Touchdown! (Image © Elmer van Hest)
(Image © Elmer van Hest)
Our turn on finals. (Image © Elmer van Hest)
Two thumbs up for the M-346 Master Advanced Jet Trainer. (Image © Elmer van Hest)
Two thumbs up for the M-346 Master Advanced Jet Trainer. (Image © Elmer van Hest)

The Starfighter flies again – in Europe

It was 9 years since Europe saw its last flying Starfighter. Or was it? Norwegians on Wednesday 28 September once more had the opportunity to see and hear a flying Starfighter, as a two seater CF-104 took off from Bodø airbase after a lengthy restoration proces. Europe has a flying Starfighter again!

The US has Lockheed F-104s participating in the airshow circuit, but Europe was cut off from flying Starfighters after the last Italian F-104s retired in 2007. That has now changed because of a Norwegian project to bring back to life an F-104 that was stuck on the ground for the previous 33 years.

The F-104 took off from Bodø for its first flight in all those years, immediately producing that famous howling sound with its General Electric J79 engine. Hear it in the clip below.

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First Polish Master rolled out

Leonardo Finmeccanica rolled out the first of eight M-346 Master trainer jets for Poland on Monday 6 June. The aircraft was unveiled at the Leonardo Finmeccanica production site in Venegono, home of all production for the M-346.

The jet wears a two tone camouflage and the emblem of Dêblin airbase below its windshield. The Polish M-346s will be based at Dêblin, where they replace the TS-11 Iskras that have been in use for many decades.

The Masters will prepare future jet pilots for F-16 operations. The first jet will now undergo a flight test program to certify bespoke systems chosen by the Polish Air Force, such as the brake parachute. It will then be delivered to Poland by the end of the year along with a second aircraft. Deliveries will be completed by November 2017.

The M-346 is a product of Alenia Aermacchi, now part of Leonardo Aircraft and part of Leonardo Finmeccanica, and so far has been ordered by the Air Forces of Italy (18), Singapore (12), Israel (30) and Poland (8) for a total of 68 orders. A follow on order from Poland seems likely.

1,000 hours for T-346 in Italy

The Italian Air Force reached 1,000 flying hours on the Leonardo Finmeccanica T-346 this week. This milestone was celebrated by instructor pilots, students and other crew of 212 squadron at Lecce airbase in southern Italy.

The 1K hours were clocked since August 2014, when the first T-346 Masters arrived in Lecce. At first the type was used to train instructor pilots, who in turn started to use the jets to train student pilots in October 2015. The Italian Air Force uses the T-346 as a phase IV trainer, which prepares students for the the final step towards fast combat jets.

The first four Italian student have now completed phase IV training on the T-346. Meanwhile, Dutch pilots are also using the Italian made jet for training. A new version of the T-346, marked T-100, is being pitched as the next fast jet trainer for the US Air Force.