The installation and commissioning of over 130 units of advanced production equipment were successfully concluded by the Perm-based enterprise UEC-STAR, which is a subsidiary of the United Engine Corporation (UEC) within Russia’s Rostec State Corporation, in 2025. The technical and production requirements of UEC-STAR were explicitly addressed by the newly deployed machining centers, milling systems, turning machines, and other specialized units. Their introduction marks a major step toward increasing manufacturing throughput and accelerating the production of key units for the PD-8 and PD-14 aircraft engines, which power Russia’s next-generation civil aircraft programs, including the Superjet and the MC-21.
The modernization of UEC-STAR’s production base forms part of a broader industrial strategy pursued by UEC to strengthen domestic capabilities in aircraft engine manufacturing. UEC-STAR is a specialized enterprise within the corporation that concentrates on the development and production of automatic control systems for gas-turbine engines. This includes hydromechanical units and digital electronic regulators. These systems play a decisive role in ensuring stable engine operation, fuel efficiency, and compliance with modern reliability standards.
Large-Scale Modernization of the Machine-Tool Fleet
The extensive renewal of its machine-tool fleet was one of UEC-STAR’s most noteworthy industrial accomplishments in 2025. Across various production facilities, over 130 units of new equipment were delivered and installed. This modernization program includes high-performance milling machining centers, turret lathes, surface-grinding and universal cylindrical-grinding machines, as well as vacuum and shaft furnaces designed for advanced heat treatment processes.
The implementation of these systems enables UEC-STAR to optimize manufacturing workflows, streamline technological chains, and significantly reduce non-productive delay. The enterprise reduces its reliance on external suppliers and enhances production efficiency and process stability by replacing aging equipment with modern, domestically produced machines. This is especially crucial for aviation components, as they require precision, consistency, and repeatability.
The new equipment establishes the technical foundation for a consistent increase in quality and output, as stated by Ilya Kulnevsky, the Chief Engineer of UEC-STAR. He also mentioned that the enterprise intends to become proficient in the machining of components for the RED-8 and RED-14 electronic engine regulators on newly installed five-axis machining centers in 2026. These regulators are indispensable for the PD-8 and PD-14 engines’ transition to large-scale serial production.
Five-Axis Machining Centers and Complex Geometry Processing
The deployment of five-axis machining centers in the mechanical production area is a critical component of the modernization initiative. Three additional machines are presently undergoing final commissioning and calibration, while eight VFC-800V five-axis machining centers have already been commissioned at UEC-STAR. These machines were developed and manufactured in accordance with the enterprise’s technical specifications, taking into account the unique requirements of aviation component production.
The five-axis centers are capable of performing a variety of machining operations in a single setup, such as drilling, precision hole machining, thread cutting, straight-line milling, and complex contour milling. This multifunctionality enables UEC-STAR to streamline operations that were previously necessitated by multiple machines, thereby enhancing dimensional accuracy and reducing setup time.
These capabilities are particularly critical for components used in electronic engine control systems, which are characterized by intricate geometries and precise tolerances. The risk of cumulative errors is considerably reduced and the overall quality of the product is improved by processing parts in a single clamping. Consequently, the implementation of five-axis machining directly contributes to the increased reliability and extended service life of engine control units.
Advanced Metal Cutting and Material Preparation Technologies
UEC-STAR has introduced new equipment for high-precision metal cutting and material preparation in addition to machining centers. These technologies are critical at the early stages of production, where the quality of blanks directly affects the efficiency and accuracy of subsequent machining operations.
The forging and pressing factory has been equipped with a modern laser cutting system, which facilitates the precise and expeditious cutting of metal sheets and profiles. A comparable laser-based plotter has been procured for the galvanic-thermal shop to facilitate specialized cutting operations. In the interim, the tool shop has acquired a water-jet cutting complex that is specifically engineered to handle large and dense components.
High-strength alloys can be processed without thermal distortion, which is why water-jet cutting is particularly advantageous in the aviation manufacturing industry. This guarantees that the material properties remain unaltered, which is crucial for components that are subjected to high mechanical and thermal loads during engine operation. The use of laser and water-jet technologies also improves edge quality, reduces the need for secondary finishing, and minimizes material waste.
Supporting PD-8 and PD-14 Engine Programs
The production ramp-up of the PD-8 and PD-14 engines, which are cornerstones of Russia’s civil aviation engine strategy, is closely linked to the modernization of UEC-STAR. The PD-14 is a high-bypass turbofan of the future that was designed for the MC-21 aircraft. It is equipped with digital control systems, sophisticated materials, and aerodynamic solutions to enhance fuel efficiency and reduce emissions.
The PD-8, which is derived from the PD-14 core, is designed for regional aircraft, including the Superjet. It is instrumental in the technological independence of Russia’s regional aviation fleet and the replacement of foreign-produced powerplants. The thrust control, engine responsiveness, and operational safety of both engines are directly influenced by the electronic regulators and hydromechanical units manufactured by UEC-STAR.
The UEC-STAR program allows UEC to synchronize engine assembly schedules with aircraft production plans, thereby minimizing bottlenecks and enhancing the overall stability of the program by extending its production capabilities.
Strategic Importance and Long-Term Outlook
The investment in new equipment at UEC-STAR is indicative of a long-term strategy that is designed to fortify the domestic aircraft engine industry in Russia. The enterprise intends to continue expanding its production capacity in the coming years, with a particular emphasis on the serial manufacturing of engine control units for current and future UEC engine programs, in accordance with an investment agreement with regional authorities.
In addition to the immediate production gains, the modernization strengthens technological sovereignty by integrating advanced manufacturing capabilities into the domestic industrial base. It also creates opportunities for workforce upskilling, as operators and engineers gain experience working with complex, digitally controlled machine tools.
In conclusion,
The commissioning of more than 130 units of advanced production equipment at UEC-STAR in 2025 represents a major milestone for both the enterprise and the United Engine Corporation as a whole. By upgrading its machine-tool fleet and introducing cutting-edge machining and cutting technologies, UEC-STAR significantly increases production throughput, improves component quality, and strengthens its role in supporting the PD-8 and PD-14 engine programs.
This modernization initiative not only expedites ongoing aircraft engine projects but also establishes a strong technological foundation for future advancements, thereby solidifying UEC’s status as a fundamental component of Russia’s civil aviation sector.