The F-35 Lightning II Joint Strike Fighter program, the Department of Defense’s most expensive weapon system program, is grappling with modernization setbacks and espionage threats.
The Government Accountability Office (GAO) has reported significant cost growth and delayed schedules in the F-35’s Block 4 modernization efforts, initially pegged at $10.6 billion with a 2026 completion.
The estimated completion has now shifted to 2029, with costs ballooning to $16.5 billion as the program has grown from 66 to 80 capabilities.
The DOD’s report to Congress regarding the Block 4 initiative fails to differentiate between cost increases stemming from originally planned Block capabilities and those arising from the incorporation of additional features.
This lack of distinction leaves Congress without a clear understanding of the factors contributing to the escalating expenses associated with the F-35 modernization program.
Further complicating the modernization initiative, Technology Refresh 3 (TR-3), a suite of hardware and software upgrades critical for enabling many of Block 4’s future capabilities, has yet to be installed on production aircraft, resulting in services withholding acceptance of new aircraft.
Compounding this issue, the F-35’s power and thermal management systems, necessary for cooling heat-generating subsystems, are overtaxed, causing the engines to work beyond design parameters, potentially leading to a hefty $38 billion in additional maintenance costs over the aircraft’s lifespan.
The GAO has advised the DOD to treat the engine and thermal management modernization as a distinct program, separate cost, schedule, and performance benchmarks for effective management.
The GAO report titled “F-35 Sustainment: Costs Continue to Rise While Planned Use and Availability Has Decreased,” released on April 15, underscores the challenges in affordability and readiness that are familiar to the F-35 program.
It also acknowledges the positive advancements in program affordability and sustainment, particularly in terms of sustainability.
The Joint Program Office (JPO) stated that they are actively implementing short-term initiatives and long-term strategies to reduce costs and enhance availability and mission capability across the F-35 fleet.
They emphasized that the actual aircraft Cost Per Tail Per Year and Cost Per Flight Hour are on a downward trend.
According to the JPO, the program has realized a 34% enhancement in the Department of Defense F-35 Cost per Tail per Year (CPTPY) from 2014 to 2022 ($9.4M to $6.2M) and a 61% improvement in the Department of Defense F-35 Cost per Flying Hour (CPFH) from 2014 to 2022 ($86.8K to $33.6K) when adjusted for constant year 2012 dollars.
Despite facing economic challenges and disruptions in the supply chain, the program remains committed to enhancing affordability. The JPO emphasized that efforts are ongoing to inject affordability into the program.
While the GAO accurately acknowledges the overall increase in program costs, attributing it to an extended F-35 service life and growth in requirements, the JPO highlighted that between 2018 and 2023, the estimated lifecycle end date of the F-35 was extended from 2077 to 2088. This 11-year extension in operations and logistics drove the cost increases referenced by the GAO. The F-35 program is mandated to calculate comprehensive overall costs spanning a 52-year period, encompassing expenses from spare parts to fuel to organic maintenance hours.
Relevant articles:
– F-35 Joint Strike Fighter: More Actions Needed to Explain Cost Growth and Support Engine Modernization Decision, Government Accountability Office (GAO) (.gov)
– 35 Program Pushes Back On GAO, Says Costs Coming Down, Air & Space Forces Magazine
– GAO Report on F, USNI News