Honeywell has unveiled a software-based solution to boost the F-35’s power generation by 25%, offering the Pentagon a potential low-risk alternative to costly hardware replacements for the stealth fighter’s overtaxed electrical systems. The aerospace systems manufacturer claims its approach could deliver immediate performance improvements while saving an estimated $7 billion in lifecycle costs compared to competitors’ complete system replacement proposals.
Addressing the F-35’s Power Crisis
The F-35’s Power and Thermal Management System (PTMS) has struggled to keep pace with the jet’s evolving sensor and communications capabilities, creating a cooling capacity deficit that strains the single F135 engine. Honeywell’s Director of Technical Sales Tony Rich revealed the company’s software update could increase output to 40kW – sufficient for the upcoming Block 4 upgrades – without modifying existing hardware. For longer-term needs beyond 2029, Honeywell proposes minimal hardware changes to achieve 80kW output while maintaining 95% component commonality.
Competing Visions for F-35 Upgrades
The proposal sets up a strategic competition with RTX subsidiary Collins Aerospace, which is developing a complete PTMS replacement called the Enhanced Power and Cooling System (EPACS). Collins recently tested an EPACS demonstrator claiming 80kW capacity without airframe modifications. This rivalry mirrors the earlier F135 engine upgrade debate, where Pratt & Whitney’s conservative core upgrade ultimately prevailed over GE’s clean-sheet adaptive engine design due to cost and compatibility concerns.
Operational and Maintenance Advantages
Honeywell emphasizes its solution’s logistical benefits, requiring just one week per aircraft for implementation versus seven weeks for a full system replacement. The company argues this approach would minimize disruptions to maintenance operations and supply chains while reducing retraining requirements for ground crews. These factors proved decisive in the F135 upgrade competition and could similarly influence the PTMS decision.
Pending Pentagon Decision
The F-35 Joint Program Office has yet to formalize requirements for the PTMS upgrade as it prioritizes the delayed Technical Refresh 3 certification. Both Honeywell and Collins continue refining their proposals using internal R&D funds while awaiting official specifications. Industry analysts suggest the Pentagon may favor Honeywell’s incremental approach given budget constraints and the urgent need to field Block 4 capabilities.
Future F-35 Enhancement Pathways
The power system debate occurs alongside broader discussions about the F-35’s long-term evolution, including Lockheed Martin’s “fifth-generation-plus” concept and former President Trump’s controversial “F-55” twin-engine proposal. These competing visions highlight the ongoing challenge of balancing immediate operational needs with the jet’s 50-year service horizon. Honeywell’s phased upgrade strategy appears designed to accommodate both near-term requirements and future growth potential.
