The UH-60 Black Hawk has been the rugged workhorse of U.S. Army aviation for nearly 50 years, with around 4,000 examples currently in service with 36 nations worldwide. Many of these helicopters, and new aircraft coming off the line, are set to fly as far out as 2070, and Sikorsky is curating a suite of upgrades to keep them valuable assets for the future fight. A new “digital backbone” is designed to underpin swift technological insertions such as launched effects, with related initiatives including the provision of more power to lug greater payloads, and the fully-autonomous U-Hawk cargo drone variant.

“As part of an overall “Black Hawk 2070” modernization effort we’re developing a number of complementary capabilities, including our U-Hawk uncrewed cargo variant, which we plan to fly later this year,” Jason Wrigley, Sikorsky’s director of business development for Black Hawk, told TWZ at the company’s Stratford plant in Connecticut.

“A new digital backbone for the Black Hawk is at an advanced design phase in our labs and it’s designed to provide interfaces throughout the aircraft that will provide power, data, a network, cooling and most importantly, open architecture interfaces that enable the easy integration of new equipment, such as sensors. We see this as a core building block for the next generation of Black Hawk, along with new engines and other airframe improvements designed to futureproof the platform.”

The new digital backbone is designed to work in concert with a modern, software-driven strategy that meets the Army’s Modular Open Systems Approach and the desire to add technologies cheaper, faster, and more easily. Wrigley says that as customers identify new capabilities and needs for their Black Hawks, the digital backbone will be sufficiently efficient to permit customization even on a mission-by-mission basis. Sikorsky is also introducing a new modular nose to the H-60, which is reconfigurable with sufficient volume to support even more sensors and electronics.

“There’s a big focus on open architecture and that ability to quickly plug-and-play,” says Wrigley. “The new modular nose will change the look of the Black Hawk up front to provide even more space for equipment that will work directly with the new digital architecture.”

The new modular nose will give the Black Hawk more than twice the internal volume of the original nose section and it’s designed to provide space for internal electronics and an integrated mount for external sensor pods. It is designed to provide sufficient space to accommodate electronics that enable roles such as search and rescue, drone control, and flying in degraded environments, and it will also house some of the equipment required as the Black Hawk’s autonomous capabilities expand.

Joshua Powers spent 22 years as an Army Aviation officer flying the Black Hawk, and he’s well qualified for his new role with Sikorsky handling business development for rapid capabilities insertions. “Army units know the Black Hawk inside out; how to fly it, maintain it, and use it to maximum effect. The upgrades we are developing will bring new capabilities faster, without time-consuming and complex changes to sustainment, training, and operations, plus we are adding more range, more payload, and more power to meet the demands of the Indo-Pacific region.”

“I find it amazing to pair new technology with a rugged platform like the Black Hawk. These new innovations are needed to meet the needs of the new complex battlefield. The fight I fought in Iraq is very different from the current operating environment and what future warriors are going to go up against, and what we’re asking them to do is very different from what came before.”

Bringing autonomous co-pilots to the Black Hawk

Autonomy is a central pillar of Sikorsky’s strategy for the future Black Hawk. The company’s MATRIX autonomy software is now being matured on a UH-60M variant, and while it’s not necessarily designed to completely replace pilots, MATRIX will assume some of their workload, making flying safer and simpler as mission sets grow increasingly complex and dangerous. “Pilots that are controlling collaborative drones, for example, need to be able to focus on the drone mission, and autonomy will help lighten their cognitive load,” explains Wrigley.

“The standard Black Hawk crew operates with two pilots. Adding our MATRIX autonomy system gives the operator options – a single pilot could fly without an unbearable workload and still fulfil a mission commander role, for example. The Army could then operate the Black Hawk with no pilots at all when that’s the appropriate option.”

Sikorsky’s MATRIX autonomy has been developed on the company’s UH-60A fly-by-wire Optionally Piloted Black Hawk, which has been tested by Sikorsky and Army aviators. MATRIX has accumulated more than 1,000 flight hours across 500 tests and demonstrations. It has already been integrated on over 20 different platforms, including on the Black Hawk for testing by the Defense Advanced Research Projects Agency (DARPA) and the U.S. Army in multiple exercises.

“We delivered the first UH-60MX to the Army earlier this year,” says Wrigley. The delivery marked the first full authority fly-by-wire and optionally-piloted UH-60 in the Army fleet. “They are using it for testing and soldier feedback to develop tactics, techniques and procedures for the autonomous Black Hawk. We have since received a contract to deliver three more MX aircraft to the Army.” 

MATRIX autonomy kits have now been installed on all three U.S. Army Black Hawk models; the UH-60A, UH-60L and UH-60M. Sikorsky plans to incorporate autonomy options into all Black Hawks as they are built, plus the MATRIX system will be able to be retrofitted to existing examples.

Powers is well aware of the benefits autonomy will provide from complex combat operations to more mundane day-to-day missions. “Flying at night and seeing the tracer fire coming up at you, things like that, I honestly feel that’s not the big threat. It’s when you’re going to land and there’s just a big dust cloud. When you’re tired, you aren’t as focused. Having MATRIX, whether that’s with one, two, or no pilots, it’s about that reduced workload on the mission. Pilots won’t be as fatigued, plus they have the safety net of a fully autonomous aircraft that can, if needed, land in all of those difficult environments. It will give commanders more operational flexibility and the ability to mitigate risk in less-than-ideal conditions dictated by the enemy or weather.”

“The Black Hawk operation isn’t just about pilots, it’s also that integrated four-person crew. As a pilot, you’re relying on your senses and also on the guys in the back to watch out and tell you where you’re going. MATRIX is just going to help that team effort and put you in a better position to bring the crew back safely. It integrates all the systems and sensors and uses altitude, airspeed, radar altimeter, drift indications, and puts the fly-by-wire technology to where it can make rapid adjustments and changes based on what it’s seeing with the sensors.”

The volume of testing, the maturity, and the confidence in MATRIX helped Sikorsky to develop the S-70UAS, or U-Hawk, which was unveiled in 2025. The U-Hawk project essentially removes the cockpit and its associated equipment from a Black Hawk and replaces the front end with cargo doors to provide a huge internal space as a supply drone.

“We acquired a used UH-60L Black Hawk as the template for our initial U-Hawk. We added the clamshell doors and that was the actual aircraft that we showed at AUSA last year,” says Wrigley. “Since then we’ve been adding the fly-by-wire and integrating the MATRIX autonomy. It’s currently in our innovations hangar in Bridgeport, Connecticut, getting the final work done and it will make its first flight as a U-Hawk later this year.”

Sikorsky sees the U-Hawk as a natural evolution for the Black Hawk in contested logistics missions, when cargo needs to be moved but the threat is sufficiently high that it drives a need for uncrewed platforms to tackle the mission. 

“We’re spending a lot of time on the U-Hawk and its roles. As well as being an uncrewed cargo helicopter, it can also be a truck that can carry a large volume of launched effects,” explains Wrigley. “There are Black Hawk models on the market right now that are being divested, and we see those as being an ideal option for conversion to U-Hawk configuration to affordably introduce this capability to the market.”

Drone dispenser

The integration of small drones dubbed ‘launched effects’ into rotary-wing operations is a major initiative from the Army as a new means to collect intelligence for commanders on the battlefield, relay communications, jam and distract enemy emitters, and act as loitering munitions. These mini air-launched drones can be carried and fired from stub-wing-mounted launchers, with other concepts seeing larger volumes of them carried inside the cabin as a “mega-pack,” with Sikorsky seeing both as being highly-applicable to both the Black Hawk and the U-Hawk.

This is exactly the kind of capability that the digital backbone in the Black Hawk is intended to open the door to; installing plug-and-play drone command kits, which could enable the Black Hawk to act as a “drone mothership” to launch, task, and command swarms of multi-mission launched effects.

The Army tested its latest operational concepts for launched effects during the Project Convergence Capstone 6 demonstration event this summer. This annual exercise is designed to develop concepts and tactics as well as gather soldier feedback, as it works to transition new systems into service. The latest exercise built on previous launched effects testing on the Black Hawk, when a UH-60M deployed Anduril’s Altius-700 launched effects that then operated as an autonomous hunter-killer team to locate targets, share data on those targets, and then strike them, without the need for the Black Hawk to expose itself to threats.

“As a young Black Hawk pilot, the OH-58 Kiowa Warrior was the primary scout platform, but it was limited by range and its ability to be detected,” explains Joshua Powers. “Today, we launch small drones that can remain unseen and they can give us real-time feedback. Launched effects make our lift assets more capable.”

“We see the Black Hawk as the aircraft capable of carrying, deploying and then acting as an airborne mission command node for launched effects,” adds Jason Wrigley. “In the operational environment of the future, it’s really about the mass of those launched effects. This isn’t about carrying one or two of them, this is about carrying and controlling a large number of them.”

“We’ve tested them on the stub-wings, but we are also exploring what we call “quiver” – that large number of launched effects inside the cabin in that “mega-pack.” This creates additional opportunities for mass that we think is going to be really critical. We’ve done a lot of operational analysis in concert with the Army on what the right mix of launched effects might be to extend the standoff range of the aircraft to improve survivability – which is of course what it’s all about – but the right mix will ultimately come down to the mission. We have seen a lot of testing over the past few years, so we do believe this is a capability that can be introduced operationally soon on the Black Hawk.”

More power for more missions

To support the increased lift that might be needed for a missionized Black Hawk lugging large payloads, including an arsenal of launched effects, Sikorsky is well along in development of a new engine that is designed to create over 1,000 pounds of increased payload capacity and increased range for the Black Hawk. The T901 Improved Turbine Engine (ITE) from GE Aerospace provides 50 percent more horsepower over the existing T700 engines in the UH-60M.

“One of the key building blocks of the future of the Black Hawk are the twin ITEs as we look to expand the mission capability and the utility of this aircraft for decades to come,” explains Wrigley. Sikorsky began initial testing of the first UH-60M with ITE in January 2025. “We are actively in the test program right now at our test facility in West Palm Beach, Florida. The twin ITEs in each Black Hawk and that additional power translates into some pretty significant operational opportunities. Since our first flight with ITE in May 2025 we’ve flown the aircraft with the new engine for over 50 hours and up to 17,000 ft above sea level.”

Sikorsky is accompanying the addition of the new engines with a significant expansion of the fuel tank to increase capacity and range. This is being done without impinging on cabin volume and thus retaining the important ability to transport 11 combat troops, while increasing range by around 100 nautical miles. “The T901 also improves fuel efficiency and eases maintenance – so overall we are really improving the payload capacity of the aircraft. We’ll be getting to the milestone C production decision on ITE within the next couple of years, and at that point it will become a core element of the Black Hawk program going forward,” Wrigley explains.

Building Black Hawks

Touring the Black Hawk production line in Stratford, Connecticut, it’s a hive of activity. Many of the major components for each helicopter are manufactured here. The long final assembly line sees teams of workers busily constructing UH-60M and HH-60M medevac Black Hawks for both domestic and foreign military sales customers, along with new HH-60W Combat Rescue Helicopters for the U.S. Air Force and MH-60R Seahawks.

“We’re designing all of these upgrades with the intent that they will all be available off the production line in new build aircraft, as well as in kit form for upgrades to existing assets in the field,” notes Wrigley. “Here in Stratford in what we call the “back shop” we build all the rotor blades, gearboxes, and many other components that go into each aircraft. We are already thinking ahead and we’ve invested significantly into additive manufacturing, with 11 parts on the Black Hawk today that are additively manufactured. It’s a great place to start, but there’s a long way to go and we’re working on qualifying more challenging components and load-bearing parts.”

Cohesively, the digital backbone, larger fuel tank, new engines, and the new modular nose will all be introduced on the production floor in the coming years to pave the way for that increased payload capacity to carry fully-equipped combat troops, supplies, and all the new kit needed for the future fight and the Black Hawk’s role as a multi-mission forward battlefield node. The autonomous U-Hawk and the optionally piloted flexibility afforded by MATRIX – all of these pieces of the future Black Hawk are presently coming together under an overarching effort.

“The future Black Hawk will be that complement to the future long-range MV-75 Cheyenne II,” says Powers. “These won’t be a one-for-one replacement for every Black Hawk currently in the fleet – the MV-75 has a specific purpose and function that the Black Hawk isn’t designed to do. What the Black Hawk can do with these new upgrades is shape the battlefield and with its autonomy be out there flying missions into contested environments.”

“Those homeland missions are equally necessary. I recall talking about this in flight school when choosing an aircraft to fly, how it’s one thing to be deployed on combat missions, but it’s also about being back in the homeland on disaster relief when you need the Black Hawk to go out and save lives, those kinds of missions the Army National Guard does – it really underlines the importance and versatility of the Black Hawk.”

Over the past 50 years and looking ahead to the next 50, continuing the proven legacy of the Black Hawk will mean constant evolution to meet new missions and needs. Sikorsky’s task is for all of these new elements to meld into a future Black Hawk that’s ready to roll off this production line soon, that still also provides the same dependable, rugged capability for the Army at home or overseas, well into the future.

The post Sikorsky’s “Black Hawk 2070” Strategy Includes Drones, New Engines, And Flying The Pilotless U-Hawk This Year appeared first on TWZ.

The U.S. Air Force has stood up a new squadron at Andrews Air Force Base to manage the arrival of HH-60W Jolly Green II helicopters to replace aging UH-1N Twin Hueys. Originally designed for combat search and rescue (CSAR) missions, the HH-60Ws assigned to the 5th Helicopter Squadron will be in a specialized configuration to take on the tasks of ferrying VIPs around the nation’s capital and supporting continuity of government plans. Questions have been raised about using Jolly Green IIs in these roles, and how this may impact the ability of the overall fleet of these helicopters to meet CSAR demands.

The Air Force held a ceremony at Andrews yesterday to mark the formal activation of the 5th Helicopter Squadron, also sometimes abbreviated as 5 HS. The 1st Helicopter Squadron (1 HS), with its UH-1Ns, will continue to operate throughout the transition to the HH-60W, which is expected to be completed in 2030, to avoid any gaps in capacity to meet critical operational requirements. A total of 26 Jolly Green IIs are set to be based at the facility, which is situated just outside Washington, D.C., a one-for-one replacement for the Twin Hueys that are there now. The arrival of the new helicopters will also lead to a small increase in total personnel, 60 in total, at Andrews.

The Air Force originally planned to supplant all of its UH-1Ns worldwide with new MH-139 Grey Wolf helicopters, which is a more direct replacement in terms of size and capability. The service is still acquiring MH-139s to supplant UH-1Ns elsewhere, including ones assigned to Air Force Global Strike Command (AFGSC) units that help provide security around Minuteman III intercontinental ballistic missile (ICBM) silos. We will come back to this later on.

“The HH-60W’s increased speed, range and carrying capacity will better deliver safe operations for U.S. senior leaders, service members, and the communities around the region,” the Air Force said in a press release regarding the 5th Helicopter Squadron’s activation.

The Jolly Green II also has in-flight refueling capability, something that is not found on the UH-1N or MH-139, and could be very valuable for missions around Washington, D.C. The HH-60Ws heading to Andrews are set to receive additional modifications, including to the main cabin seating arrangement, communications suite, and defensive capabilities, as you can read more about here.

“In the next few years, the 5 HS will train aircrew and maintainers, establish operational and maintenance processes, and receive new aircraft as it prepares to execute the national security mission within the National Capital Region,” the release yesterday added.

National Capital Region (NCR) refers to a larger area that surrounds Washington, D.C., proper. Air Force operations in and around the NCR are primarily managed through a unit called the Air Force District of Washington (AFDW).

The HH-60Ws will be taking over an AFDW mission set from the UH-1Ns that currently includes daily airlift sorties transporting U.S. and foreign VIPs around the nation’s capital. The helicopters will also be in position to swing into action as part of continuity of government plans. In such a scenario, the Jolly Green IIs would be tasked to help rush senior officials and lawmakers to safety to ensure the continued functioning of federal authorities following an attack or a similarly serious contingency. 1st Helicopter Squadron’s role in responding to the terrorist attack on the Pentagon on 9/11 was highlighted during the activation ceremony at Andrews yesterday.

The NCR presents particular challenges for crisis response missions and routine day-to-day flight operations. The airspace around Washington, D.C., is most densely defended and heavily monitored anywhere in the United States, and packed full of military and civilian air traffic every day. Where and when military helicopters can operate over the nation’s capital has been a hot topic of debate since a fatal mid-air collision involving an Army UH-60 Black Hawk and a PSA Airlines Bombardier CRJ700 regional jet in January 2025. The Black Hawk was conducting a continuity of government training flight at the time. This has been more recently highlighted by an incident involving a Marine One helicopter carrying President Donald Trump earlier this month. A subsequent Federal Aviation Administration (FAA) investigation has highlighted communication issues and factors tied to the construction of a new helipad at the White House.

It is also worth noting here that Marine Helicopter Squadron One (HMX-1), the primary unit responsible for the Marine One presidential helicopter mission, would play a role in any continuity of government scenario in the NCR. Helicopters from the U.S. Park Police, as well as ones belonging to other law enforcement and civilian agencies, would be utilized, too.

As mentioned, there are significant questions about the impacts of basing HH-60Ws at Andrews will have on the rest of the Air Force’s Jolly Green II fleet. This is something TWZ highlighted when the Air Force confirmed it was moving ahead with the AFDW HH-60W plan with the release of its 2027 Fiscal Year budget request earlier this year.

A particular issue is the Air Force’s decision years ago to scale back total purchases of HH-60Ws, from 113 helicopters down to 91. If the service does not order more Jolly Green IIs in the coming years, this will mean that roughly a third of the entire fleet will be assigned to the AFDW mission.

The Air Force previously confirmed the plan will involve taking HH-60Ws out of “back up inventory.” In the past, the service has defended this decision as being “more cost effective” than a move to “procure additional MH-139A aircraft” to meet AFDW requirements. Whether or not there were other specific operational considerations that factored into the decision to use Jolly Green IIs to meet these needs instead is unknown. The acquisition plan for the Grey Wolf has also been significantly truncated, with the Air Force now planning to buy just 56 of these helicopters instead of 80.

“The MH-139A Grey Wolf was competitively selected to replace the UH-1N for intercontinental ballistic missile security and National Capital Region missions, including continuity of government and transport of United States government officials and security forces,” members of the House Armed Services Committee wrote in a report accompanying a draft of the annual policy bill, or National Defense Authorization Act (NDAA), for the 2027 Fiscal Year, back in May. “The committee remains concerned regarding the justification for transitioning these missions to an alternate rotary-wing platform and seeks additional details on cost and operational implications.”

At that time, the House Armed Services Committee explicitly directed “the Secretary of the Air Force to submit a report to the congressional defense committees not later than December 1, 2026, assessing operational, cost, infrastructure, and readiness impacts of assigning any non-MH-139A rotary-wing aircraft to continuity of government and transport of United States government officials and security forces in the National Capital Region.” The lawmakers stressed that the report had to include “a comparison of procurement cost, cost per flight hour, infrastructure and aircraft modification requirements, and training and manpower impacts” and an assessment of the cost, schedule, and operational disruption associated with required upgrades to Joint Base Andrews facilities for each aircraft type.”

Separate questions have been raised in recent years about the utility of traditional CSAR helicopters in future operations, especially in the context of a high-end fight, such as one between the United States and China in the Pacific. Air Force officials openly talked about exploring alternatives for rescuing aircrew downed deep inside contested environments, but details about those plans remained limited.

At the same time, demand for traditional CSAR capabilities has certainly not gone away entirely. This was underscored by the operation to retrieve the crew of an F-15E Strike Eagle that went down inside Iran in April. HH-60Ws were part of the larger force package sent into Iranian airspace to help recover those aviators.

Wild footage from a USAF C-130 fueling two helicopters over Iran shared by telegram channels. The cars & the dialect are Iranian and from southwest. pic.twitter.com/K9cufOOY26

— Ramin Khanizadeh (@RKhanizadeh) April 3, 2026

Footage of Iranian police firing small arms at a pair of USAF HH-60Ws searching for the downed F-15E crew earlier today. pic.twitter.com/9SwhyhY1Aw

— OSINTtechnical (@Osinttechnical) April 3, 2026

In the meantime, the Air Force’s UH-1Ns, a type the service first began operating in the early 1970s. are only getting older and harder to sustain, too. Three of the UH-1Ns currently assigned to 1st Helicopter Squadron saw combat during the Vietnam War. Just last week, one of the unit’s Twin Hueys made a precautionary landing in an open field in Maryland “after experiencing unusual mechanical noise” while on a training flight. This is hardly the first time such an incident has occurred.

There is a possibility that Congress could more directly intervene in the Air Force’s move to start flying HH-60Ws around Washington, D.C. With the expectation that UH-1Ns will remain in service at Andrews for another four years, there is time for the service’s own plans to evolve further.

With the activation of 5th Helicopter Squadron, the Air Force has now taken an important step toward an all-new helicopter force in the nation’s capital.

Contact the author: joe@twz.com

The post USAF Stands Up Unit To Fly HH-60W Helicopters In Doomsday Evacuation Role In Nation’s Capital appeared first on TWZ.