Russia has entered another important phase in the development of its long-range aviation program after two experimental Ilyushin airliners—the modernized Il-96-400M and the Il-96-300—completed a ferry flight to Khabarovsk Airport in the country’s Far East. The aircraft will undergo extensive flight evaluations to test new equipment and upgraded systems, generating valuable data for Russia’s widebody aviation sector.
The aircraft’s deployment to Khabarovsk reflects Russian aerospace engineers’ efforts to modernize domestically designed long-haul passenger planes and lay the groundwork for next-generation engine developments like the PD-35.
Flight Test Campaign Begins in Russia’s Far East
Ilyushin specialists will conduct a series of demonstration flights from Khabarovsk Airport to assess the newly installed avionics, navigation equipment, and modernized onboard systems, according to officials in the Khabarovsk Territory.
The Far Eastern location is well-suited for advanced flight-testing activities due to its operational flexibility, diverse weather conditions, and expansive airspace. It is anticipated that engineers will gather a substantial amount of performance data to verify the enhanced systems in real-world operational scenarios.
Engineers are also able to directly compare the behavior of legacy and upgraded systems during similar flight profiles as a result of the Il-96-400M’s and Il-96-300’s participation.
The Il-96-400M is the most advanced widebody aircraft in Russia to date.
The Il-96-400M represents the most significant modernization of the Il-96 family since the aircraft first entered service.
The maiden flight of its prototype in 2023 marked the start of an ambitious initiative to modernize Russia’s indigenous widebody platform. The aircraft’s fuselage has been extended by approximately 9.35 meters in comparison to the predecessor, the Il-96-300, resulting in a significant increase in passenger capacity to approximately 370 passengers in a single-class configuration.
The aircraft is powered by four enhanced PS-90A1 turbofan engines, which offer superior efficiency and increased thrust in comparison to their predecessors.
The aircraft includes new Russian-built avionics and navigation systems that meet international standards for long-range operations over remote and oceanic routes, enhancing its capabilities while reducing reliance on imported equipment. The aircraft’s operational capabilities are substantially improved by these enhancements, which simultaneously decrease dependence on imported equipment.
Modernization Is Not Limited to the Airframe
The current testing campaign is not merely concerned with ensuring the aircraft’s safety during flight.
It is expected that a major portion of the attention will be directed toward the validation of integrated digital systems, flight management functions, communication equipment, navigation accuracy, and other upgraded onboard technologies that were developed as part of Russia’s import-substitution strategy.
Russian manufacturers have prioritized developing domestically produced avionics and aircraft systems because accessing Western aerospace technology has become complex due to Western sanctions. One of the country’s flagship initiatives that illustrates this transition is the Il-96-400M.
Successful testing could facilitate additional modernization work across the Il-96 fleet and support future specialized variants for government, cargo, or commercial applications.
The PD-35: Russia’s Future High-Throughput Engine
Although the Il-96-400M is currently equipped with PS-90A1 engines, there is a growing emphasis on the future PD-35 engine program.
The engine is designed to serve as the nation’s inaugural domestically developed ultra-high-thrust turbofan, capable of propelling future heavy transport and widebody passenger aircraft.
Nevertheless, the process of development has not been entirely seamless.
The financial statements released by the Aviadvigatel design bureau of United Engine Corporation indicated that the company experienced losses in 2025 as a result of the temporary suspension of funding for research and development under the PD-35 program. The company reported a net loss of approximately 663 million rubles, primarily due to the interruption in financing for the large-thrust engine project, while revenue decreased to approximately 16.6 billion rubles.
The company has confirmed that work on the family of large-thrust engines, which are based on the PD-35 gas generator, has resumed and is currently underway, despite the financial setback.
Additive Manufacturing Emerges as a Critical Technology
The extensive use of additive manufacturing is one of the most remarkable features of the PD-35 program.
United Engine Corporation has already manufactured over 2,300 engine components through the application of sophisticated 3D-printing technologies.
The strength, durability, long-term reliability, and manufacturing consistency of these components are currently being assessed during ongoing ground testing. Engineers regard additive manufacturing as one of the primary technologies that has the potential to reduce production cycles and facilitate the development of more intricate and lightweight engine designs.
The technology demonstrator has already completed over fifty ground test runs, which have provided engineers with valuable data to refine the design prior to eventual certification.
A Collection of Future Engines
The PD-35 is no longer considered a standalone engine.
Simultaneously, Russian engine developers are developing the PD-26, a derivative engine that is based on the same technological platform but is intended to generate less thrust.
Engineers can build an entire family of engines while reducing development risk, lowering costs, and increasing commonality between future powerplants by using the PD-35 gas generator as a common foundation. The strategy is similar to that of major global engine manufacturers, who utilize a shared core to support a variety of engine variants for various aircraft categories.
It is expected that the PD-26 will provide power to future passenger and transport aircraft that require less thrust than the flagship PD-35, while still using a number of the same advanced technologies.
Could the Il-96 Receive PD-35 Engines?
According to industry representatives, developing a new widebody aircraft entirely based on the PD-35 could take up to a decade.
The Il-96-400M has been the subject of more discussion as a practical platform for the eventual integration of the new engine once it reaches maturity as a result of the lengthy timeline.
The fuel efficiency, payload capability, range, and operating economics of Russia’s sole domestically developed long-range widebody airliner could be considerably improved, as well as the service life, by a future re-engined Il-96 that is equipped with PD-35-derived powerplants.
At present, the Il-96-400M’s improved systems are being validated during the ongoing Khabarovsk flight trials, which is the immediate priority. The aircraft’s readiness for future duties will be assessed through these tests, which will also furnish engineers with valuable operational data for ongoing modernization. Simultaneously, the PD-35 and PD-26 engine families are making significant strides in the development of the next iteration of Russian long-haul aviation. The ongoing aircraft trials and engine development efforts are complementary steps that are being taken to enhance Russia’s independent capabilities in the widebody commercial aircraft sector and to guarantee that future long-range airliners are powered solely by domestic technologies.