Embraer Launches KC-390 Assembly Line in the US for Air Force Contracts

Embraer is set to establish a KC-390 Millennium assembly line in the United States, a strategic move aimed at competing for future contracts with the US Air Force. The Brazilian aerospace manufacturer has confirmed that it is developing detailed site plans for potential locations across the country, which will enable local assembly and supply of this versatile twin-jet transport aircraft. This initiative aligns with domestic sourcing requirements, positioning the KC-390 as a strong candidate for the Air Force’s Next Generation Air Refueling System (NGAS) program.

Frederico Lemos, Chief Commercial Officer of Embraer Defense & Security, expressed the company’s commitment to increasing its investment in the US, stating they are “100% committed [to] invest more in the US.” Establishing local assembly operations would ensure the KC-390 complies with the Buy American Act, which mandates that federal procurement needs be sourced domestically.

Currently, the KC-390 is assembled at Embraer’s facility in Gavião Peixoto, Brazil, where it already incorporates a significant amount of US-manufactured components. Approximately 59 US aerospace firms contribute parts and systems for the KC-390, accounting for over half of its total purchased materials. Key suppliers include major companies such as Collins Aerospace, L3Harris, Raytheon, BAE Systems, and the propulsion consortium International Aero Engines, which provides the aircraft’s twin V2500 turbofans.

Competing for the Future of Aerial Refueling

The US Air Force is currently in the process of replacing its aging fleet of Boeing KC-135 tankers with the more modern KC-46A. This transition addresses the lifecycle challenges associated with the decades-old Stratotanker and aims to provide a platform capable of operating in contested environments. Under the NGAS program, the Air Force is seeking to develop a “survivable tanker” that can withstand contemporary threats.

Originally, NGAS was envisioned as a purpose-built stealth aircraft, likely featuring a blended-wing-body configuration. However, recent shifts in strategy have led officials to explore a “systems-based approach” that could incorporate electronic warfare capabilities to enhance conventional aircraft, along with advanced air superiority assets such as uncrewed fighters and future sixth-generation jets.

At the recent Air & Space Forces Association conference, General John Lamontagne, Chief of Air Mobility Command, indicated that “just about every option is on the table.” The Air Force is considering a variety of possibilities, ranging from a clean-sheet stealth tanker to modified business jets or “signature-managed” conventional aircraft. Among these potential candidates is a US-specific variant of Embraer’s KC-390 Millennium.

Strategic Moves Ahead of the RFI Deadline

Embraer plans to formally respond to the US Air Force’s Request for Information (RFI) for the Next Generation Air Refueling System by October 24, 2023. The submission will detail how a US-built variant of the KC-390 could meet the service’s requirements for a future refueling platform. This response will likely include enhancements such as electronic warfare systems aimed at improving the aircraft’s survivability.

The KC-390 is already in service or on order with 11 operators worldwide, spanning multiple European and Asian air forces. Embraer hopes that its new assembly line in the US will bolster its case in this competitive environment. Nonetheless, the company faces significant competition from established defense manufacturers like Boeing, Lockheed Martin, and Airbus. Additionally, systems integrators such as L3Harris and Sierra Nevada, known for their expertise in converting business jets into military platforms, may also vie for the same contracts.

By establishing local assembly and supply operations in the US, Embraer aims to level the playing field against domestic competitors, enhancing its position in the evolving landscape of military aviation.