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Sukhoi: The History and Innovations of Russian Aircraft Manufacturing

The History of a Legendary Design Bureau

The Sukhoi Design Bureau (OKB Sukhoi) was founded in 1939 by the prominent aircraft designer Pavel Osipovich Sukhoi as an experimental design bureau. Over its more than 80-year history, the company has created over 100 types of aircraft and their modifications, of which about 60 were built in series. In total, more than 10,000 "Su" aircraft have been produced and delivered to 30 countries around the world.

Key historical milestones:

• 1939 – creation of the Design Bureau under the leadership of P.O. Sukhoi
• 1945-1949 – development of the first jet fighter Su-9
• 1950-1960s – creation of the family of supersonic fighters Su-7/Su-9/Su-11
• 1970-1980s – development of the legendary Su-27
• 2000s – creation of the Su-34, Su-35S and the beginning of work on the Su-57
• 2006 – inclusion in the United Aircraft Corporation (UAC)
• 2007 – entry into the civil aviation market with the Sukhoi Superjet 100 project

Unique Military Developments

Su-27 and its Modifications

The Su-27 fighter, developed in the 1970s, became a real breakthrough in military aircraft construction. Many experts consider it the best fighter of the 20th century. A whole family was created on the basis of this aircraft:

• Su-30 – a multi-role fighter with an extended range
• Su-33 – a carrier-based fighter for aircraft-carrying cruisers
• Su-34 – a fighter-bomber with a unique "side-by-side" cockpit
• Su-35S – a deeply modernized multi-role fighter

A key difference between Sukhoi aircraft and their Western counterparts is their super-maneuverability, achieved through the controlled thrust vector of the engines, which allows them to perform unique figures such as the "Pugachev's Cobra" and the "Bell".

Su-57 – Fifth Generation Fighter

The newest Russian fighter Su-57 (PAK FA) combines the functions of a strike aircraft and a fighter. Features:

• "Stealth" technology (low visibility)
• Supersonic cruising speed
• Advanced avionics with elements of artificial intelligence
• Integrated control system
• Powerful weapons, including the Kinzhal hypersonic missiles

The cost of one Su-57 is estimated at $35-50 million, which is significantly lower than the prices of similar Western fifth-generation fighters (F-35 – about $80-100 million, F-22 – over $150 million).

Civil Aviation – Sukhoi Superjet 100

An important step for the Sukhoi Design Bureau was its entry into the civil aviation market with the Sukhoi Superjet 100 (SSJ100) short-haul passenger aircraft, designed to carry 98 passengers over a distance of up to 3,000 km.

SSJ100 Features:

• Modern aerodynamics
• Advanced avionics from Thales
• SaM146 engines, developed jointly with the French Safran
• Spacious cabin with increased passenger comfort

The cost of the SSJ100 in its basic configuration is about $35 million, which makes it price-competitive in its segment. Currently, work is underway on the SSJ New project with an increased share of Russian components and improved characteristics.

Innovative Technologies

The Sukhoi Design Bureau actively implements innovative technologies in its developments:

• Composite materials – in the Su-57 design, the proportion of composites is about 25%
• Integrated modular avionics – allows to significantly increase reliability and reduce equipment weight
• Plasma technologies – research in the field of plasma stealth technologies and flow control
• Additive technologies – 3D printing of complex titanium parts
• Digital design – a full cycle of aircraft development in a digital environment

Service Support and Parts

The company provides a full life cycle of its aircraft:

• For military aircraft, a system of service centers operates in Russia and abroad
• An international maintenance network has been created for the SSJ100
• A program for modernizing old modifications is being implemented (for example, Su-25SM, Su-30SM)
• The average service life of Sukhoi military aircraft is 30-40 years with proper maintenance

A challenge remains the limited resource of some components, which is solved through import substitution programs and the creation of extended spare parts stocks.

Promising Developments

The Sukhoi Design Bureau is actively working on a number of promising projects:

• Su-75 "Checkmate" – a light single-engine fifth-generation fighter with low visibility and the possibility of unmanned control, estimated cost – $25-30 million
• Su-57E – export version of the fifth-generation fighter
• S-70 "Okhotnik" – a heavy strike drone working in conjunction with the Su-57
• SSJ New – a modernized version of the Superjet with improved characteristics and import substitution
• A promising long-range bomber-missile carrier

United Aircraft Corporation (UAC)

Since 2006, Sukhoi has been part of the United Aircraft Corporation, the largest Russian aircraft holding company, created by decree of the President of the Russian Federation to consolidate the potential of the industry.

The UAC unites key aircraft manufacturing enterprises in Russia:

• PJSC "Sukhoi"
• MiG Design Bureau
• "Tupolev"
• "Ilyushin"
• "Irkut"
• "Yakovlev"
• Voronezh Joint Stock Aircraft Building Company (VASO)
• Ulyanovsk Aviation Plant "Aviastar-SP"
• Other industry enterprises

In 2018, a controlling stake in the UAC was transferred to the Rostec State Corporation, which completed the process of consolidating aircraft assets.

The UAC development strategy until 2035 provides for:

• Increasing the share of civil products to 40-45%
• Entry into the global market with competitive products
• Active import substitution
• Digitalization of production processes
• Creation of new aircraft for various purposes

Differences from Other Manufacturers

The Sukhoi Design Bureau differs from many competitors in a number of characteristic features:

• Unique aerodynamics – integrated layout with forward horizontal tail
• Super-maneuverability – the ability of aircraft to perform maneuvers at critical angles of attack
• Multi-mode – efficient operation in a wide range of altitudes and speeds
• Durability and unpretentiousness – the ability to operate from unpaved airfields
• The concept of "open architecture" – the ability to integrate various systems and weapons

Role in World Aviation

The Sukhoi Company occupies about 15% of the global market for tactical combat aircraft. Modern Su-30, Su-35 and Su-57 fighters form the basis of the air power of Russia and a number of other countries.

In the civil aviation segment, the company occupies a modest share so far, but the SSJ100 project and its development demonstrate serious ambitions to expand its presence in this market.

Thanks to a combination of high flight performance and relatively low aircraft cost, as well as a willingness to transfer technology, Sukhoi remains an attractive partner for many countries seeking to develop their military and civil aviation.