BAE Systems has reached a major “business end” phase in developing its Future Combat Air Demonstrator (FCAD), which will de-risk technologies for the Global Combat Air Programme (GCAP). The company reported that around 75% of the demonstrator—by volume—has already been manufactured, with major structural sections produced over the past 12–18 months and a rollout targeted for the end of 2027.

Aviation Week reported that the publication was able to view the front, center, and rear fuselage sections being built at BAE’s site in Samlesbury, while the double-delta wings are being built at Warton. The fuselage sections have been aligned on jigs, and the center fuselage section is described as revealing two deep internal weapons bays positioned ahead of the main landing gear—suggesting a larger internal weapons volume than the F-35’s shallower bays.

The demonstrator’s intake-fuselage junction is manufactured as a single component using hot isostatic pressing (HIP), a process BAE said enables shapes not feasible with conventional techniques. Similar HIP methods have also been used to produce titanium actuator cradles for large trailing-edge control surfaces.

On the assembly timeline, BAE said the company plans to transport the fuselage (“cigar”) to Warton next year so it can be mated with the wings and vertical stabilizers. BAE reported that three wings and three vertical stabilizers have been produced—two each for installation and a third of each for structural testing.

The piece also notes that BAE is working toward military airworthiness certification, described as the first time the company has undertaken the process from scratch. BAE said test pilots have accumulated more than 300 hours in the simulator and that tools are generating much of the fly-by-wire flight-control software ahead of first flight.