NAL Saras
| Company type | Government-owned research and development organization |
|---|---|
| Industry | Aerospace |
| Founded | 1959 |
| Headquarters | Bangalore , India |
Key people | Jitendra J. Jadhav (Director, as of 2017) |
| Products | Saras aircraft |
| Owner | Government of India |
| Parent | Council of Scientific and Industrial Research (CSIR) |
The NAL Saras () represents India's pioneering multi-role civilian aircraft within the light transport segment, developed by the National Aerospace Laboratories (NAL).
Following announcements of cancellation in January 2016, the initiative was reinstated in February 2017. Subsequently, in February 2019, the Ministry of Finance granted approval for commencing production of this airliner.
Development
During the mid-1980s, the Research Council tasked the National Aerospace Laboratories (NAL) with evaluating India's civil aviation requirements and investigating the feasibility of establishing a domestic aerospace industry. A detailed techno-economic feasibility analysis for a versatile light transport aircraft (originally termed LTA and renamed SARAS in 1993) was undertaken. The November 1989 study revealed a substantial market demand for a 9–14 seat LTA, forecasting potential sales between 250 and 350 units over a decade. NAL finalized this report in 1990 and initiated efforts to identify an industrial collaborator.
The project commenced in 1991 with Russian cooperation (notably, Myasishchev was developing a similar Duet aircraft), but financial difficulties led to Russia withdrawing prematurely. Additionally, U.S. sanctions imposed in 1998 after India's nuclear tests nearly brought development to a halt. Official project sanctioning occurred on 24 September 1999, targeting an inaugural flight by March 2001. The Saras prototype (PT1) achieved its maiden flight at HAL Bangalore Airport on 29 May 2004.
Initial design specifications aimed for a maximum takeoff weight of 6,100 kg, payload capacity of 1,232 kg, cruising speeds exceeding 600 km/h, endurance up to six hours, a maximum altitude of 12 km (with cruising at approximately 10.5 km), short takeoff and landing capability around 600 m, climb rates near 12 m/s, cabin noise limited to 78 dB, and operating ranges from 600 km with full seating (19 passengers) to 2,000 km with reduced passenger load (eight passengers). Operational costs were targeted at ₹5 per kilometer.
Although the design empty weight was approximately 4,125 kg, the first prototype weighed around 5,118 kg. To address this excess weight, composite materials were introduced for wings and tail sections by the third prototype stage. Saras-PT2 featured an airframe incorporating lighter composites aiming to reduce PT1’s overweight status by about 400 kg within an overall excess nearing 900 kg. Propulsion is provided by two Canadian Pratt & Whitney turboprop engines arranged in a pusher configuration.
Upgrades to the initial prototype include installation of more powerful Pratt & Whitney Canada PT6A-67A engines rated at 1,200 hp each and advanced flight control systems. The enhanced PT1 was planned for its first flight by late 2011, with certification expected by 2013 and deliveries commencing in 2014.
Revised status
By 20 January 2016, development of Saras had been suspended due to funding reductions finalized by late 2013 at National Aerospace Laboratories (NAL). Engineering personnel were reassigned to projects deemed higher priority.
The second prototype exceeded its design weight by roughly 500 kg (design weight: 4,125 kg). Meanwhile, the third prototype remained unflown as NAL pursued renewed financial support.
In October 2016, governmental discussions took place regarding revival prospects for the program. The Council for Scientific and Industrial Research (CSIR) began reassessing plans alongside potential budget augmentation.
On 14 February 2017, the refurbished first prototype was transferred to the Indian Air Force's Aircraft & Systems Testing Establishment (ASTE) for conducting low-speed ground evaluations. NAL director Jitendra J. Jadhav set a target for resuming flight tests by mid-2017; however, program officials anticipated this might occur between August and September.
An upgraded Saras variant completed high-speed taxi trials on 2 January 2018 at Bangalore. This Saras-PTN1 model reduced seating capacity from nineteen to fourteen passengers and incorporated improvements such as advanced avionics systems, radar enhancements, upgraded wing flap actuators, environmental control systems, engine flap actuators, and refined flight control mechanisms.
The redesigned prototype undertook its maiden flight on 24 January 2018 from HAL Airport lasting approximately forty minutes while reaching altitudes of around , followed by nearly twenty additional flights aimed at finalizing production configurations. During Aero India 2019, an allocation of ₹6,000 crores was announced to support production following certification of this enhanced version. Weight was decreased by about nine hundred kilograms alongside avionics modernization. The second test flight lasted twenty-five minutes on 21 February 2018.
Further advancements include installation of twin engines delivering 1,200 shaft horsepower each and propellers measuring 104 inches in diameter to satisfy climb performance criteria. CSIR is collaborating with the Defence Research and Development Organisation (DRDO) toward creating an indigenous turboprop engine specifically for Saras. Hindustan Aeronautics Limited (HAL) has been designated as the manufacturer at its Kanpur facility.
Mark 2
The CSIR-NAL is advancing the Saras Mk2, a 19-seat regional aircraft. This initiative has received governmental financial backing. After completing fundamental pre-production evaluations, NAL aims to secure certification within four years, followed by an 18-month production timeline. Design and prototyping efforts utilize Dassault Systèmes’ 3DEXPERIENCE and DraftSight software. Wind tunnel experiments featuring a tractor configuration were planned for November 2019. For the fiscal year 2021–22, the Department of Scientific and Industrial Research (DSIR) sought an additional ₹100 crore funding. NAL targets a unit price of ₹50 crore for the Saras Mk2, which is competitive against the ₹55 crore cost of the Dornier 228, noted for its unpressurized cabin and operational altitude constraints. To ensure production feasibility, NAL is pursuing government procurement of 50 to 60 units.
At Wings India 2022 on 27 March, NAL introduced a 16-seat air ambulance version, with Bengaluru-based International Critical Care Air Transfer Team (ICATT) signing a letter of intent for two aircraft.
On 14 May 2022, taxi trials commenced on the Saras PT1N featuring a domestically developed digital anti-skid braking system designed to facilitate safer landings on shorter runways. This sophisticated brake-by-wire electro-hydraulic mechanism, managed by a flight control computer, will be incorporated into the Saras Mk2 following successful validation. Paras Defence delivered the full glass cockpit avionics suite in March 2023.
By April 2024, NAL projects the Mark-2’s inaugural flight for late 2027, a delay from the initial 2026–27 schedule. Most materials have been sourced; fabrication will begin after finalizing design drawings. While NAL is responsible for most components, certain metallic parts will be outsourced to Hindustan Aeronautics Limited, with other suppliers handling fuselage assemblies. Avionics systems are procured from Genesis. Two prototypes are planned, with the first flight expected after approximately one year of taxi testing. The Saras PT1N prototype functions as a technology demonstrator for brake control and environmental management systems.
Orders
The Indian Air Force has placed an order with National Aerospace Laboratories, Bangalore for 15 Saras aircraft, with potential demand extending to an additional 45 units. A memorandum of understanding between NAL and the IAF covers sale of these 15 aircraft, which will be manufactured at Hindustan Aeronautics Ltd’s Kanpur facility. These aircraft are intended to support coastal surveillance and pilot training missions.
An allocation of ₹6,000 crores was made in early 2019 to support production efforts. The initial IAF order of 15 may grow to between 120 and 140 units over time.
Operators
Indian Air Force – Planned fleet of 60 aircraft
- Phase 1 – Acquisition of 15 aircraft
- Phase 2 – Acquisition of an additional 45 aircraft
Incidents and accidents
On 6 March 2009, a tragic accident occurred when two Indian Air Force test pilots, Wing Commanders Praveen Kotekoppa and Dipesh Shah, along with Flight Test Engineer Squadron Leader Ilayaraja, lost their lives as the second Saras prototype crashed near Bidadi, approximately 30 km from Bangalore. An official inquiry determined that improper engine relight procedures devised by the manufacturer and followed by the crew at too low an altitude led to rapid altitude loss and abnormal flight characteristics resulting in the crash.
Additional resources
- NAL Saras information
- A Remarkable Achievement
- Status of Saras Second Prototype
- HAL to produce India’s inaugural passenger aircraft
Technical specifications: