US Air Force creates innovative hybrid aircraft from damaged F-35 jets

In the United States, a remarkable feat of engineering was accomplished by the 388th Fighter Wing based at Hill Air Force Base in Utah. The team successfully merged two damaged F-35A fighters into one operational aircraft, affectionately named the "Franken-bird." This project was initiated in January 2020, following damage incidents involving one jet from a nose-gear collapse and another suffering from an engine fire. The innovative approach to aircraft restoration attracted attention within the military and aerospace communities. The combined efforts required interagency collaboration, involving the F-35 Joint Program Office, Ogden Air Logistics Complex, and Lockheed Martin alongside the 388th Fighter Wing. With a total cost of $6 million, the rebuilt Franken-bird is significantly cheaper than a brand new F-35A, which typically costs around $82 million. The successful merger demonstrates the Air Force's commitment to sustainability and operational efficiency, addressing the challenges of maintaining high-performance military aircraft. With the completion of extensive restoration work, including the reinstallation of landing gear and new flight control systems, the aircraft took its inaugural flight on January 16, 2025. This achievement as the first of its kind not only showcases the technical capabilities of USAF maintenance personnel but also highlights the importance of innovative solutions in extending the lifespan of existing military assets. As the Franken-bird approaches final certification, it is expected to be put back into service shortly, further enhancing the capabilities of the 388th Fighter Wing. Moving forward, the hybrid aircraft will serve as a test case for future projects, potentially leading to more such creative restorations. The unique nature of this initiative illustrates how the military is adapting to modern challenges, and it may open the door for more collaborations between defense companies and military maintenance teams. As the Franken-bird prepares to return to duty, its successful transformation embodies the resourcefulness and ingenuity of the U.S. Air Force in enhancing its fleet's performance.