The Navy’s unmanned MQ-25 Stingray will reach initial operating capability in September 2025, approximately six months later than planned, a program official said.
The incorporation of the new ground control station initially shifted the program’s IOC date to February 2025, according to Capt. Sam Messer, program manager of unmanned carrier aviation.
However, IOC is now pushed back to September due to delays in building the engineering and manufacturing development aircraft because of “supplier quality issues,” Messer told Inside Defense in a statement.
The Navy plans to award a low-rate initial production contract to Boeing in the second quarter of fiscal year 2023 for an initial quantity of 12 aircraft across three years, according to an annual Government Accountability Office review of the Defense Department's major weapon systems.
However, “given the challenges experienced on the development contract, production costs may be significantly higher than currently estimated,” GAO said in its June report.
The engineering to finalize the aircraft design is “fully captured” in the engineering and manufacturing development contract and will not affect the cost of LRIP, Messer said.
The program office is currently finalizing the LRIP request for proposal, Messer added.
The aircraft’s cost will be known once the government releases an RFP, Boeing submits a proposal, negotiations take place and settlement is reached, Messer said.
“Cost and schedule impacts to the program are still being evaluated as the government works with Boeing to definitize the contract change for the new ground control station,” Messer said.
The MQ-25 program of record is a new start in FY-23.
The program is comprised of 76 aircraft, according to service budget documents. Of the 76, four are engineering development models and three are system demonstration test articles -- all of which were funded using research and development funds.
The remaining 69 aircraft will be funded with Navy aircraft procurement funds, the service states.
The government watchdog’s annual report noted that the MQ-25’s engine inlet’s shape could lead to engine damage during flight.
“Program officials have yet to determine how they will address the issue but stated that changes in the engine design could range in complexity," GAO said.
The engine’s inlet performance is still being assessed and deficiencies identified during testing are being used to define any potential solution to the inlet distortion, Messer said.
“The program is still assessing any cost/schedule impacts from this early learning, but at this point none are driving [the] program’s critical path,” Messer said.
Program officials told GAO that they expect to complete a production readiness review and manufacturing readiness assessment by October 2022.
However, “Boeing is currently not contractually required to provide manufacturing readiness level data. Consequently, the program lacks insight into whether Boeing will be able to consistently produce the aircraft while meeting cost, schedule, and quality expectations at the start of production,” GAO said.
The program plans to complete a production readiness review and manufacturing readiness assessment in June 2023, Messer said.
The program is still on track to complete software integration efforts by IOC in 2025, Messer added.