HAL to Produce 100 CATS Warriors Annually with Private Sector Collaboration, Boosting IAF’s Capabilities at $5-10 Million Per Unit

State-owned aerospace giant Hindustan Aeronautics Limited (HAL) is making rapid strides in the development of its Combat Air Teaming System (CATS) Warrior, an advanced unmanned aerial vehicle (UAV) designed to operate alongside manned fighter jets. With an ambitious production target of up to 100 units annually, HAL is actively expanding its partnerships with private sector firms to accelerate manufacturing and meet the Indian Air Force’s (IAF) growing demand for force-multiplying technologies.

The CATS Warrior: A Game-Changer for the IAF

First unveiled as a full-scale model at Aero India 2025, the CATS Warrior represents a significant step forward in India’s indigenous drone warfare capabilities. Designed to work in tandem with manned aircraft such as the Tejas, Su-30 MKI, and Rafale, the drone is expected to execute high-risk missions, including deep-strike operations, electronic warfare, and target reconnaissance. By accompanying crewed fighters into contested airspace, the CATS Warrior can reduce risk to human pilots while enhancing the overall effectiveness of air combat missions.

The concept of 'manned-unmanned teaming' (MUM-T) forms the backbone of this initiative. Under this model, a single fighter jet pilot could control a small swarm of Warriors, each performing a specific role—such as jamming enemy radars, engaging ground targets, or acting as a decoy to confuse adversaries. This strategy mirrors global developments, with the U.S. Air Force’s Skyborg project and Australia’s MQ-28 Ghost Bat program also pursuing similar capabilities.

Cost-Effective and Scalable Production

A key factor driving the IAF’s interest in the CATS Warrior is its affordability. With an estimated unit cost ranging between $5 million and $10 million, the drone presents a cost-effective alternative to traditional fighter jets, which can cost upwards of $50 million each. This allows for larger fleet deployments, increasing combat flexibility without excessively straining India’s defense budget.

HAL’s plan to ramp up production to 100 units per year is supported by a growing network of private sector suppliers. Companies specializing in advanced composites, avionics, and propulsion systems are being integrated into the supply chain to ensure efficient manufacturing. A major milestone was reached in early 2025 when Tata Advanced Systems delivered a prototype airframe structure for the CATS Warrior, signaling the maturation of HAL’s industrial ecosystem for unmanned systems.

Trials and Future Prospects

Despite the promising outlook, the CATS Warrior program must clear critical hurdles before full-scale induction into the IAF. Flight trials are expected to begin in late 2025 or early 2026, during which the aircraft will undergo rigorous evaluation. The IAF will assess key performance parameters, such as its Autonomous Take-Off and Landing (ATOL) capability, secure data link reliability, and mission payload effectiveness.

Successful trials could pave the way for large-scale orders, with experts speculating that the IAF might procure hundreds of units to bridge its fighter squadron shortfall. Currently operating with 31 active fighter squadrons against a sanctioned strength of 42, the IAF views the CATS Warrior as a crucial enabler in maintaining aerial superiority.

Beyond domestic use, HAL’s mass production capability also opens doors for potential exports, aligning with India’s broader defense export ambitions. Given the increasing global interest in loyal wingman UAVs, the CATS Warrior could find international buyers, further boosting India’s standing in the global defense industry.

With HAL’s determined push towards serial production and the IAF’s increasing reliance on unmanned systems, the CATS Warrior is poised to become a pivotal asset in India’s future air combat strategy. The coming years will determine whether this ambitious program can fulfill its potential, transforming India’s aerial warfare capabilities while reducing dependence on expensive foreign fighter jets.