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USAF Assessing Feasibility Of Restarting C-17 Production As Part Of Its Future Airlift Vision

The U.S. Air Force has been taking a new look at the feasibility of restarting production of the C-17 Globemaster III cargo plane as part of its still-evolving next-generation airlift plans. The service also continues to explore a wide range of next-generation aerial refueling concepts, including new stealthy and/or uncrewed tankers, but a firm vision for the way forward there has yet to emerge.

Air Force Lt. Gen. Daniel Tulley, head of Air Mobility Command (AMC), shared new details about future airlift and aerial refueling efforts, with TWZ and other outlets at a roundtable at the Air & Space Forces Association’s (AFA) 2026 Air, Space & Cyber Conference.

On the airlift side, the Air Force’s stated plan to date is to replace both the C-17A and C-5M Galaxy with a single Next-Generation Airlift (NGAL) platform, starting in the mid-2040s. Separately, the service is pursuing what could be a family of future aerial refueling capabilities under what is now called the Advanced Tanker Systems (ATS) program. Very broadly speaking, ATS presents a path toward what might come after the retirement of the aging KC-135 tanker fleet, though those aircraft are still expected to keep flying for years to come. The Air Force is also moving to further expand its fleet of newer KC-46A tankers in the interim, but persistent technical and other issues with that design continue to present hurdles.

A US Air Force C-5, at left, together with one of the sevice’s C-17s, at right. USAF
A KC-135, at right, prepares to link with a KC-46, at left, during a test. USAF

At the roundtable today, Lt. Gen. Tulley was asked explicitly about restarting C-17 production. The manufacturer of those aircraft, Boeing, shuttered that line in 2015. The company also just marked the 35th anniversary of the design’s first flight yesterday.

“Heck yeah, but with a caveat, right?” Tulley said in response. “So we were just asking this question over the course of last week, and it’s in the context of next-generation airlift. So we are about to embark on the Analysis of Alternatives to replace the C-17 and replace the C-5. All options are on the table.”

“There’s always the option to service life extend the C-17, but the [production restart] question came up,” he continued. “I’ve heard this my entire career. Once we terminate an assembly line, can we ever bring it back? Does somebody store all the machinery and the dies and whatnot, and can you bring that out? So we’re asking that question.”

“But then whatever that answer is from the vendors, what will be the price tag associated with that?” he added. “You have to ask yourself, okay, is rebuilding a C-17 even if you make improvements – and there’s a loose analogy with the C-130J, [a] much more modern, capable variant of the C-130E [author’s note: the C-130J evolved more directly from the C-130H variant] I first learned to fly – if you do that with the C-17, is that the best move? Or are there new technologies that we can incorporate into it so that it can defend itself, so that it’s connected, it’s networked, it does all the things that maybe the current C-17 doesn’t do?”

“We’re looking into it as part of the Analysis of Alternatives. I’m hopeful that we’ll get to answer that question.”

In June, the House Armed Services Committee also directed the U.S. Air Force to prepare a formal briefing on the matter of new C-17 production in a report accompanying a draft of the annual defense policy bill, or National Defense Authorization Act (NDAA), for Fiscal Year 2027.

The RAND Corporation did conduct a detailed, independent analysis more than a decade ago that assessed the costs and complexities that could come from Boeing building more C-17As, as well as other variants and derivatives of the design. RAND’s conclusion was that any of the courses of action would require billions of dollars of new investment and entail risks, as you can read more about in more detail here.

Foreign participation in a new C-17 production run could help at least defray costs. Australia, Canada, India, Kuwait, Qatar, the United Arab Emirates, and the United Kingdom all currently fly Globemaster IIIs. The Strategic Airlift Capability (SAC) initiative, a multinational arrangement with several European members, as well as the United States, also operates three of these aircraft.

Boeing told TWZ directly in June that unnamed C-17 operators had been reaching out about the prospect of restarting the production line, and that the company was “encouraged” by those discussions.

As Lt. Gen. Tulley stressed, there are significant questions about whether buying new-production C-17s, even with substantial improvements, is not only feasible, but a good use of resources. The Air Force’s Globemaster III fleet today continues to prove itself to be critical to the U.S. military’s ability to project power globally, and is in very high demand right now, especially amid the ongoing conflict with Iran.

The Air Force’s desire to replace both the C-17 and C-5, which are very different aircraft in form and function, could still easily lead the service down a different route. Boeing is not the only one looking at future NGAL opportunities. Another company, Radia, has been very actively pitching a clean-sheet design that is physically bigger than either the C-17 and the C-5, and that is geared toward greater operational flexibility, at the Air Force. Radia is targeting a first flight of its aircraft, called Windrunner, by the end of the decade, but it is still in a very aspirational stage at present.

A rendering of Radia’s Windrunner design. Radia

Many questions also still remain about how the Air Force will ultimately proceed on the next-generation aerial refueling front.

“So thinking beyond the current KC-46 buy and the program extension, whatever that next tanker looks like, our Advanced Tanker System, it’s got to be connected. It’s got to be able to defend itself,” Lt. Gen. Tulley said at the roundtable. “But it begs the question: does it need to be manned? Could it be optionally manned? Could it be autonomous? Or is there a family of solutions maybe that would answer that question? So I do not believe that it has to be manned.”

The AMC head was responding to a specific question about how autonomy could play into the Air Force’s future aerial refueling plans, which included a reference ot the U.S. Navy’s MQ-25 Stingray tanker drone. The Navy just announced its first low-rate initial production contract for MQ-25s on Monday.

“I think you’re seeing that with the MQ-25 and the Navy’s work, but then, how do we, the U.S. Air Force, bring that to bear in scope, scale, and range?” Tulley continued. “An optionally manned or an unmanned tanker, at range, the ranges we need to operate at, it’s a very large aircraft. And we’re not yet to where we’re employing fully autonomous large aircraft, but the technology, I would say, is there and rapidly getting there if it’s not.”

The MQ-25 is another Boeing product, and that company has shown a rendering of a larger, land-based derivative in the past. Lockheed Martin’s Skunk Works has also put forward several advanced tanker concepts in the past, including stealthy and potentially uncrewed designs.

A rendering of a larger, land-based derivative of the MQ-25, depicted refueling from a KC-46 tanker. Boeing
One of the advanced tanker concepts Lockheed Martin’s Skunk Works has shared publicly in recent years. Lockheed Martin Skunk Works

“We will be going after how to make the tanker survive,” William Bailey, the Air Force official currently performing the duties of the Assistant Secretary of the Air Force for Acquisition, Technology and Logistics, had also told TWZ and other outlets at a separate roundtable at the Air, Space & Cyber Conference yesterday. Bailey was responding to a direct question about whether the service was moving away from the idea of a stealthy tanker as part of the ATS plan.

“So, lots of work around what do we do in the future for our tankers, and we spent a pretty dedicated effort to go through and look at what do we think those design solutions could look like,” Bailey also said. “We looked internally. We went out to industry, had those guys come back with their thoughts on how to provide a more survivable aircraft.”

“The stuff that was coming in for me might have been an incremental improvement, but [it was] not clear that that represented the next step, the next phase,” he added. “What you’ll see is we’ll take our efforts, and we’ll look at, hey, if the real question is tanker access, then let’s not constrain ourselves to just the aircraft itself and trying to make a stealthy tanker. We need a tanker to have access, so we’ll talk about all those systems that it would take to protect that tanker.”

Bailey said the question of operational “access” applied to next-generation discussions, as well.

As is the case with the Air Force’s airlift fleets, the service tankers are in high demand due to the conflict with Iran and other current operational requirements. Stress on the existing tanker force, compounded by the ever-advancing age of the KC-135s, has been a steadily growing point of concern for years now. U.S. military officials have long been drawing attention to the limits of available aerial refueling capacity to meet even routine peacetime demands. The Air Force, as well as the U.S. Navy, have also expanded their use of contractor-owned and operated tankers to perform certain non-combat aerial refueling missions to help ease this strain.

This ex-French Air Force KC-135FR tanker, now operated by private contractor Metrea, is an example of the outside aerial refueling capacity the U.S. military has been increasingly leveraging in recent years. Metrea

In the meantime, the Air Force is still pursuing upgrades for its existing airlift and tanker fleets, with heavy focus on increased network connectivity and improved self-protection capabilities.

Greater connectivity “can be a game changer, and it has been a game changer in Operation Epic Fury [against Iran],” Lt. Gen. Tulley said at today’s roundtable. “The ability for air crews to communicate, to coordinate tanker orbits and rendezvous, to pass threat information, to save lives and save aircraft has been everything we expected it to be and more.”

“We have MAF NEXUS that we’re pursuing. The goal is to have this on all mobility aircraft, whether they’re future-built and it’s incorporated, or it’s an add-on capability to existing aircraft,” he continued. “It brings edge compute, the ability to then employ AI [artificial intelligence] and much more computing core power forward on the aircraft, and it does network with the rest of the joint force and the Air Force’s battle management system.”

A picture of a US Air Force KC-135 tanker spotted earlier this year with a new large satellite communications antenna (further highlighted in the inset), underscoring work underway now to improve the network connectivity of those aircraft. Alessandro Ledda

When it comes to new options for protecting existing tankers, “nothing’s off the table,” the AMC boss added. “Whether it’s [in the] electromagnetic spectrum, whether it’s kinetic self-defense, a layered approach, we’re looking at everything to come up with what might be the best system. But it’s got to be a system that we can afford, and it’s got to be one that we can put on all the aircraft we have and the ones we’re about to build.”

Using Collaborative Combat Aircraft (CCA) or other types of drones to help provide localized defense for airlifters and tankers could be another option. The Air Force has already experimented with this, at least to a degree.

The Air Force is otherwise still clearly continuing to shape its future airlift and aerial fueling visions. As part of that work, the service is now at least considering the possibility of rebooting C-17 production.

Contact the author: joe@twz.com

The post USAF Assessing Feasibility Of Restarting C-17 Production As Part Of Its Future Airlift Vision appeared first on TWZ.

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USAF’s Fighter Drones To Make Debut In A Large Scale Exercise

U.S. Air Force Collaborative Combat Aircraft (CCA) are set to take part in a large-force employment (LFE) exercise for the first time later this year. Sending CCAs to the next iteration of the Emerald Flag test exercise is another important new stepping stone toward fielding the drones operationally.

“We have not yet done a LFE with these [CCAs], for real. The first one is going to be Emerald Flag. That’s in December,” Lt. Col. Lyndon “OTTO” Bartlett, Director of Operations for the Experimental Operations Unit (EOU) at Nellis Air Force Base in Nevada, said earlier today. “That’ll be our first tip dip of the toe in an actual force integration.”

One of the Air Force’s YFQ-44A Fury CCA drones flies together with an F-35 Joint Strike Fighter. Anduril

Bartlett was speaking during a panel at the Air & Space Forces Association’s (AFA) 2026 Air, Space & Cyber Conference, at which TWZ is in attendance. The EOU has been leading Air Force efforts to lay the groundwork for future CCA operations. The unit has already been conducting various types of testing using prototypes of the General Atomics FQ-42A Vengeance and Anduril FQ-44 Fury. The Air Force announced in June that its initial operational CCA fleet would consist of a mix of FQ-42s and FQ-44s.

The Air Force’s 96th Test Wing at Eglin Air Force Base in Florida first began hosting Emerald Flag exercises in 2020. The exercise series has historically focused heavily on demonstrating new and improved aerial networking architectures and other command and control capabilities, which will be especially critical elements for future CCA operations. Emerald Flag, with its not purely limited to the air domain, is often tied in with other large force test exercise series. Other branches of the U.S. military regularly take part, as well.

It is worth noting here that Boeing’s MQ-28 Ghost Bat, a CCA-type design, did take part in Valiant Shield 26, another LFE exercise, earlier this year. The EOU was also involved. However, the MQ-28, originally developed for the Royal Australian Air Force, is not officially part of the Air Force’s CCA program at present.

Emerald Flag in December “will, in OTTO’s mind, be the first time that we will ever do some CCA end-to-end chain [demonstration] live. That’s the first time we’ll ever be integrated in a fourth- and fifth-gen combined OCA [offensive counter air] push,” Lt. Col. Bartlett added. “It’ll be small, but those type [sic] of building blocks are where I think you get the intangibles like trust in the CCA.”

“Those learnings are going to be just as valuable as the technical, [like] does the radio work properly? Does the button I push to say ‘target’ work properly?” he continued.

A General Atomics YFQ-42A CCA drone during an earlier test flight. General Atomics

U.S. military officers, including tactical jet pilots, regularly talk about the critical need for trust in autonomous systems to perform as expected when directed in future operations. Establishing that trust, and doing so in real-world environments, is seen as foundational to answering larger outstanding questions about how CCA-type drones will be deployed, launched, recovered, supported, and otherwise operated, let alone employed tactically.

The EOU, together with other partners within the U.S. military and industry, have been working for years now to validate and improve autonomous capabilities in the virtual realm, and then test in more limited real-world contexts. Virtualized testing does offer immense benefits for rapid iterative development of the underlying software ahead of live demonstrations.

“If it’s in a simulated environment, it’s immediate,” Lt. Col. Bartlett said during the panel when asked about the “feedback loop” in testing the EOU is already taking part in. In that environment, “when the mission autonomy iterations are happening, our guys are literally with the programmers … They give the feedback, and if it’s possible to do immediately, they take that feedback. If not, then they work on it on the next turn of the software.”

Real-world testing, of course, offers opportunities to explore additional aspects of future CCA operations, including when it comes to loading weapons and maintenance. A key component of the Air Force’s vision for CCA employment is being able to forward deploy the drones to far-flung locations, including airstrips with limited infrastructure and access to logistics chains. Rapid, distributed deployments like this are central to still-evolving concepts of operations currently referred to collectively as Agile Combat Employment (ACE). The EOU has been involved in at least two rounds of ACE-focused testing this year, one at Edwards Air Force Base in California in April and another at Creech Air Force Base in Nevada in July. TWZ was the first to report on the latter event.

During the panel today, Lt. Col. Bartlett also talked more generally about work EOU has done to date. This has included exploring “sortie generation, how easy they are to maintain, [and] how small a footprint could be.”

“We’ve been pleasantly surprised. The jets are extremely easy to maintain,” he continued. “We’re at a one-to-one maintainer-to-airplane ratio, which is crazy small.”

With “CCAs, [it] seems like because they’re a little bit simpler, because their role is so focused, what we found is that just about any – not just about, but we found that any AFSC [Air Force Specialty Code; alphanumeric codes used to identify specific jobs within this service] can be trained to generate sorties to load weapons, and we’ve done some of those things already,” he further explained. “It’s our job to bring them [CCAs] out and make sure that, beyond the technical specifications of it, that we’re kind of experimenting with the more complex things like logistics, and C2 [command and control], and how do we battle manage these things.”

Airmen prepare to load an inert AIM-120 Advanced Medium Range Air-to-Air Missile onto a YFQ-44A CCA drone. USAF/Senior Airman Renee Blundon

The head of the EOU did acknowledge challenges that still have to be surmounted. This notably includes hurdles currently imposed by Federal Aviation Administration (FAA) regulations on the operation of fully uncrewed aircraft, even by the U.S. military, within U.S. airspace. This is further compounded by the explicit intention to operate CCAs with far more minimal human engagement compared to most existing drones.

“Mission autonomy is going to be the secret sauce that lets these things become decisive or not, and we’ll know that over the next couple years as that develops,” according to Bartlett. “If I were to identify the two biggest problems from the trenches of the EOU, [one] is FAA integration or policy implications to an autonomous airplane.”

“So these things don’t have pilots. They’re not RPAs [remotely-piloted aircraft]. They’re not manned fighters. They have no pilots,” he continued. “Our system is not set up for that, and that is a challenge that we are finding extremely hard to navigate through, and to not go around, but to make a policy.”

“We need to make sure the Air Force is ready for these things, to set policies that make sure the enterprise and the country is [sic] ready to receive these, and internalize an autonomous fighter that does not have a pilot that is running on a mission autonomy agent that doesn’t listen to ATC [air traffic control],” he added.

Another look at a YFQ-44A prototype during at test in 2026. USAF

The second problem, per Bartlett, is making sure the Air Force develops new internal policies and doctrine that are not “copy and pastes from old regulations” that do not take into account the specific nuances that CCAs will bring. What the service needs is “something that enables us to move quickly with these things, to weigh what we need, and to experiment with novel types of air superiority.”

All of this circles back to the discussion of trust in autonomous capabilities. It also speaks to the potential for future operations where CCAs could operate far more independently.

“It’s in the name that they’re collaborative,” Bartlett said. “Taking them out of that could technically be effective, but would not enhance the joint force the way that we see a collaborative, integrated force package to be.”

“What we need autonomously to do is written down. I won’t discuss the particulars in this forum, but we know what we need it to do, or we know what we think it really needs to do,” he noted. “We’ve structured our experimentation game plan to analyze ‘can it do those things?,’ and if not, then how do they need to be different? And then as they iterate on it, which we’ve already seen a couple times, we get that at the EOU, we get the new version down, we fly it again. Is it fixed? Yes or no.”

A General Atomics YFQ-42A seen from another angle during earlier testing. General Atomics

Some members of industry are clearly envisioning futures with different definitions of ‘collaborative’ that could lean more toward independent operations involving highly autonomous drones.

What “the whole entire program is trying to do is [figure out] what is the requirement to put out into the field to get to the warfighter and to start operating this thing this [sic; in] real time?” Robert “Otis” Winkler, Vice President of Corporate Development & National Security Programs at dronemaker Kratos, another one of the panelists, said. “The collaborative part of this makes it a much easier, I think, technical problem to be able to limit and grow the autonomy as you field this.”

“I think eventually we may see these aircraft utilized as collaborative aircraft, but not in conjunction with your traditional pulsed operation, but in support of that pulsed operation when the pulse isn’t there yet. But I do think that that is a bit of a stretch goal that’s going to be down the road.”

CCAs “have been designed really around increasing both survivability and lethality of current force packages. So there are many manned platforms that you would describe in the exact same fashion,” Jason Levin, Senior Vice President for Air Dominance and Strike at Anduril, who was also on the panel, said. He was responding here to a specific question about whether his use of the term “fighter” to describe these drones implied more emphasis on independent operations.

All of this underscores the importance of bringing CCAs to Emerald Flag in December, as well as other events in the future offering opportunities to see how the drones really fit in with other crewed platforms. The Air Force is hoping to start seeing CCAs enter operational service around the end of the decade, and have 500 of them, at least, in inventory by 2032.

During the panel today, the EOU’s Lt. Col. Bartlett made clear that “we’re going to learn a lot over the next couple years.”

Contact the author: joe@twz.com

The post USAF’s Fighter Drones To Make Debut In A Large Scale Exercise appeared first on TWZ.

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