In a groundbreaking development in the defence and aerospace industry, engineers have combined parts from two damaged F-35 aircraft to create a new model, nicknamed “Franken-Lightning,” now being prepared for flight. This project not only showcases innovative engineering but also marks a historic milestone for the F-35 programme.
Split and Reassembled Like Bread
The forward fuselage of an F-35 that suffered an engine failure on the runway was combined with the rear fuselage of another F-35 rendered unusable due to a nose landing gear failure. Through the meticulous work of skilled engineers, a fully airworthy F-35 model was rebuilt, earning its place as a first-of-its-kind achievement in aviation history.
Where Did the Parts Come From?
The project utilised components from two damaged F-35 aircraft, identified as AF-211 and AF-27. The rear fuselage of AF-211, made inoperable due to a nose landing gear failure in 2020, was merged with the intact forward fuselage of AF-27, which had sustained damage from an engine fire in 2014.
The repair process was carried out in collaboration with the F-35 Joint Program Office (JPO) and its partners. The goal was to repurpose salvageable parts into a combat-ready and flight-capable aircraft.
Steps in the Process
Initiated in December 2023, the project was undertaken by a specialised engineering team at Hill Air Force Base. The team developed innovative tools and connection systems to seamlessly integrate components from the two aircraft. This process not only enabled the successful repair but also set a roadmap for similar restoration efforts in the future.
“Franken-Lightning” Ready for Duty in 2025
The reconstructed F-35A is expected to achieve flight readiness by March 2025 and is set to take on an active role in combat operations. Dave Myers, Engineering Lead at the F-35 Joint Program Office, described the initiative as “a first in the F-35 programme and a truly exciting development. It also lays the groundwork for future projects of a similar nature.”
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