MOSCOW – Russia has officially deployed artificial intelligence (AI)-driven robotic manufacturing at the Gagarin Aircraft Plant (KnAAZ) to accelerate production of the Su-57 fighter jet.
According to defencesecurityasia.com on Tuesday (5 May), the move marks a strategic shift in Moscow’s defence-industrial doctrine to address manual labour shortages amid sanctions and wartime pressures, while also seeking to reshape the global balance of fifth-generation air power.
At the core of the expansion is the introduction of an automated robotic technology complex (RTK). According to project developers at Irkutsk National Research Technical University, the system functions as a “digital technologist” capable of autonomously generating manufacturing processes based on 3D models and real-time measurements.
Technically, the RTK fundamentally restructures the Su-57 airframe manufacturing process by replacing operator-dependent hydraulic forming with automated roller-based deformation and precision metal assembly.
Industrial robots equipped with machine vision systems and adaptive controls are capable of autonomously identifying, aligning, and processing components.
Combined with interchangeable tooling for complex curvature work and mobile robotic platforms in assembly zones, the system effectively transforms the production line into a cyber-physical system while aligning Russia’s aerospace manufacturing with global Industry 4.0 trends.
This digital transition is said to improve stealth tolerances, structural uniformity, and aerodynamic consistency, while also extending component lifespan by up to three times due to reduced human error variables.
Modernisation at KnAAZ, which remains the sole serial production facility for the Su-57, also includes new titanium processing lines, expanded galvanic production capabilities, and advanced testing hangars.
The efficiency upgrades are considered urgent as the factory’s production orders are already filled through to 2030.
Given the historically low production rate of the Su-57, estimated at only between two and ten aircraft annually, Russia is now planning an ambitious increase to deliver up to 76 aircraft by 2028, the year when full RTK implementation is targeted for completion.
Although the RTK system is regarded as highly significant, its immediate strategic value currently lies more in stabilising workflow, as Russia still faces critical vulnerabilities in composite material production.
This modernisation effort comes after a major fire in April 2026 damaged the primary composite materials workshop. The incident affected around 300 specialised components, including wing structures, control surfaces, and intake elements.
As rebuilding that capacity will take time, overall aircraft output is expected to remain constrained because the RTK system only strengthens the metal airframe production segment. As a result, short-term production increases are likely to remain incremental.
Beyond these technical constraints, the lack of independent verification regarding projected output increases also adds uncertainty to long-term production forecasts.
Nevertheless, from a geopolitical perspective, the programme reinforces Moscow’s intention to project long-term strategic persistence rather than pursue direct quantitative parity with Western fifth-generation fleets.
At the operational level, the success or delay of this expansion will affect force regeneration cycles, sortie sustainability, and the Russian Air Force’s ability to maintain credible deterrence across multiple theatres simultaneously.
If this RTK-based modernisation is successfully integrated across the entire production ecosystem, it could potentially transform the cost-efficiency metrics, production tempo, and lifecycle sustainability of the Su-57, ultimately influencing adversary threat assessments and procurement confidence among partner nations. (SF/LM)
Originally written by: Lisa Monica, Sahrudin Fiqri M
Source: IDN Financials
Published on: 7 May 2026
Link to original article: Russia deploy AI‑driven robot to speed up Su‑57 fighter jet production
