A major breakthrough in technology has taken place in Russian aviation: the MC-21 airliner has been entirely substituted with domestically produced alternatives for all composite materials. This indicates that the aircraft’s structure is no longer made of foreign composite materials. All components, including the load-bearing elements of the fin and stabilizer box structures, are now manufactured in Russia, including the wings and tail assemblies. This achievement is an important step in the nation’s attempt to ensure the technological independence of its aerospace industry.
The Federal Air Transport Agency (Rosaviatsiya) granted Yakovlev approval for a major change to the MC-21 type certificate in 2025, thereby formalizing the decision. The modification permitted the use of domestic materials in the structural components of the vertical tail and stabilizer box sections. Therefore, Russian science and industry have successfully implemented a major initiative to incorporate locally produced composite materials into the aircraft’s design.
Historical Context: From Foreign Dependence to Domestic Production
The MC-21 program was initiated in the mid-2010s as a bold attempt to modernize Russia’s narrow-body passenger fleet and compete with the most efficient and capable Western aircraft in terms of operating performance. The aircraft’s original design was heavily influenced by composite materials, which provide high strength while reducing weight, thereby enhancing aerodynamic performance and reducing fuel consumption.
In 2018, Russian aircraft manufacturers faced major difficulties as a result of sanctions, geopolitical tensions, and the suspension of foreign composite supplies. In response, domestic companies and scientific institutions initiated the development of indigenous polymer composite materials for all critical aircraft components.
The import substitution process was technically challenging and required several years. Engineers were required to do more than just develop replacement materials; they were also required to guarantee safety, structural integrity, and durability that were equivalent to or greater than those of foreign counterparts. Additionally, these materials were required to endure operational stresses that exceeded those faced in typical flight conditions, necessitating extensive testing and validation.
Composites in Modern Aviation and the Role of the MC-21
Modern commercial aircraft stand out by the use of composite materials. Carbon-fiber structures are used extensively in programs such as next-generation wide-body aircraft on a global scale, with some structures accounting for up to 50% of the airframe’s weight. One of the most innovative civilian aircraft programs in Russia, the MC-21 was designed with comparable technological objectives.
The process of substituting imported composites entailed considerably more than the production of basic materials. It necessitated the establishment of comprehensive technological chains, including the production of carbon fiber and prepreg, as well as the fabrication of large integrated structures like tail box assemblies and wing components. Leading industrial enterprises, certification bodies, and research institutions throughout the nation were mobilized by this effort.
Certification Process: Key Steps and Milestones
The certification pathway has been considerably improved by the approval of Rosaviatsiya. The validation of modifications to the MC-21 type certificate that included entirely domestic composite materials in the load-bearing elements of the vertical tail and stabilizer was finalized in December 2025.
Specialists from various aviation registers and certification centers, including major state research institutes and aerodynamic laboratories, were involved in the certification effort. Aircraft certification is highly complex and multilayered. It necessitates the confirmation of material properties, as well as detailed modeling, structural calculations, full-scale bench experiments, and real-world trials. The use of new materials in an aircraft’s structure can only be authorized by regulators after operational reliability has been demonstrated.
The objective of this thorough method is to completely remove technological threats. In an environment where foreign supplies may be unavailable, prohibitively expensive, or politically hazardous, import substitution has become particularly critical.
Leadership Commentary and Strategic Importance
Dmitry Yadrov, the director of Rosaviatsiya, observed that the Russian materials science sector has once again exhibited its capacity to swiftly develop and deliver world-class composites for civil aviation. The reliability of these materials has been verified through calculations, simulations, and testing that were conducted with the involvement of the country’s top scientific and certification institutions.
The achievement was facilitated by the close collaboration between science and industry. Engineers were able to develop new materials and build them into one of the most intricate engineering systems in modern manufacturing—an advanced passenger aircraft—all while adhering to the necessary performance standards as a result of this partnership.
The MC-21’s tail structures have been approved for the use of domestic composites, which marks the end of a critical phase of import substitution, according to Vadim Badekha, CEO of United Aircraft Corporation. The aircraft has been entirely rid of foreign materials, and the reliability of Russian alternatives has been verified through testing. The project effectively established a new sub-sector within the national composite aviation industry by fostering a comprehensive collaboration between research institutions and production enterprises.
Commercial Prospects and Serial Production
KAPO-Composit, a subsidiary of the AeroComposit organization under Yakovlev, is currently engaged in the serial production of the fin and stabilizer box structures, which are constructed from indigenous composite materials. This development indicates the localization of supply chains, in addition to technological independence.
Replacing imported materials helps stabilize manufacturing lines, reduces reliance on foreign vendors, and reduces exposure to currency fluctuations—even during periods of geopolitical uncertainty.
Concurrently, the MC-21 is still undergoing certification as a completely import-substituted plane. Currently, engineers are collaborating with the developer to certify the aircraft with newly installed domestic equipment and systems.
As part of the certification campaign, multiple prototype aircraft that are equipped with entirely localized components have already conducted test flights, which is a critical step toward commercial operation. It is anticipated that the completion of certification will facilitate the delivery of products to airlines, thereby facilitating the renewal of domestic carrier fleets.
Implications for Russia’s Aerospace Industry in the Global Context
The MC-21’s incorporation of domestic composites is a component of a more comprehensive import substitution strategy for Russia’s aviation sector. The project includes critical aircraft components, including engines, avionics, control systems, and onboard equipment, in addition to materials.
This progress is significant in a global market that has been historically dominated by Western manufacturers and is extremely competitive. The technological sovereignty of Russia is fortified and the risks associated with external restrictions are mitigated by the possession of a completely domestically developed airliner with competitive performance characteristics.
Furthermore, the composite materials sector’s expansion generates prospects that exceed internal demand. Exports of aircraft components and composite technologies, particularly to emergent aviation markets and partner nations, may be bolstered by the expertise acquired in the development of advanced aviation materials.
Conclusion: A New Status for Russian Aircraft Manufacturing
The complete replacement of foreign composite materials in the MC-21 is not just a technical achievement; it is a strategic national milestone that is designed to ensure independence from external economic and political pressures, build a resilient industrial base, and reinforce technological sovereignty.
The achievement serves as evidence that domestic scientific and manufacturing capabilities are capable of addressing some of the most intricate challenges in contemporary aviation. The success of composite import substitution has already opened a new chapter in Russian aerospace, defined by innovation, expertise, and a long-term strategic vision that has resulted in a globally competitive aircraft, while the certification process continues.
