Embraer C-390 Millennium
The Embraer C-390 Millennium is a medium-size, twin-engine, jet-powered military transport aircraft designed and produced by the Brazilian aerospace manufacturer Embraer. It is the heaviest aircraft the company has constructed to date.
Work on the project began at Embraer during the mid-2000s, with early efforts centred around a conceptual derivative of the E190 jetliner of a similar size to the Lockheed C-130 Hercules. The company was keen to use turbofan jet engines, instead of turboprops. Support for the venture was forthcoming from both the Brazilian government and the Brazilian Air Force. In May 2008, the government invested R$800 million in the project's development. In April 2009, Embraer was issued a $1.5 billion contract for two prototypes. The aircraft was initially designated C-390 before changing to KC-390 in early 2011. At the 2011 Paris Air Show, Embraer announced plans to launch a stretched version of the aircraft as a civilian freighter. Partnerships were promptly formed with various other aerospace companies on the programme, including FAdeA, ENAER, OGMA, and Boeing. A joint venture with Boeing was announced in November 2019, but quickly fell apart within six months. Major subcontractors in the aircraft's manufacturing include Aero Vodochody, BAE Systems, and Rockwell Collins.
On 3February 2015, the first of two prototypes performed its maiden flight. On 4September 2019, the first production aircraft was delivered to the Brazilian Air Force. In November 2019, during the Dubai Airshow, Embraer announced the aircraft's new name for the global market, C-390 Millennium. Several export customers for the C-390 have been secured, including the Portuguese Air Force, Hungarian Air Force, the Royal Netherlands Air and Space Force, the Austrian Air Force, and the Swedish Air Force. The C-390 can be configured to perform various conventional operations such as troop, VIP and cargo transportation, and more specialised logistical operations such as aerial refuelling as a tanker. It can carry payloads of up to, such as two fully-tracked M113 armored personnel carriers, one Boxer armoured vehicle, a Sikorsky H-60 helicopter, 74 litters with life-support equipment, up to 80 soldiers or 66 paratroopers with full gear, and loads of up to can be air dropped. Each aircraft costs around €80 million as of 2024.
Development
Studies
In the early 2000s, the Brazilian aircraft manufacturer became interested in developing its own medium-sized transport aircraft. Its initial design study was based around a high-wing derivative of its existing E190 jetliner. Between 2005 and 2007, it investigated the pairing of the wing and GE CF34 engine of the mature Embraer 190 with a cabin that was modified to function as a cargo hold, complete with a rear ramp, closed-loop fly-by-wire system, and synthetic vision.By 2006, Embraer was studying a military tactical transport design of a similar size to the Lockheed C-130 Hercules, to be powered by 17,000–22,000 lbf jet engines, such as the Pratt & Whitney PW6000 and Rolls-Royce BR715. In April 2007, Embraer publicly stated that it was studying a medium-size airlifter. Referred to by the company designation C-390, this transport aircraft was said to incorporate many of the technological solutions present on the Embraer E-Jet series and feature a rear ramp for the loading and unloading of a wide range of cargo.
In March 2008, the Brazilian government planned to invest about R$60 million in the aircraft's initial development. Simultaneously, the Brazilian Air Force was in the process of finalizing an initial purchase contract for between 22 and 30 aircraft, while Embraer was negotiating with possible partners on the programme. Two months later, the Brazilian Congress released R$800 million to be invested in the project and fund the aircraft's development. Around this time, the media claimed that the aircraft would be operated by the Brazilian Air Force and the Army and Navy, and that there were unconfirmed sales to other government agencies in the works.
Program launch
On 14 April 2009, Embraer was awarded with a $1.5 billion contract to develop and build two prototypes. At the programme launch, the design was all-new in terms of its fuselage, wing, flight deck, and engine selection. The E-190's wing were dispensed with, partly due to its limited surface area. It was also stated that the aircraft would be the operational successor to the Brazilian Air Force's C-130 fleet. According to Embraer, the selected jet engine is sufficiently resilient to dust ingestion, whereas propeller tips close to the ground are susceptible to damage. Embraer also chose the IAE V2500 engine for its efficiency under normal conditions, rather than prioritising its performance under unusual conditions, such as on the Antonov An-32.In March 2010, Embraer drew up a development schedule, upon which the first prototype aircraft was scheduled to be delivered in late 2014. In July 2010, at the Farnborough Airshow, the Brazilian Air Force announced its intent to order 28 C-390s, while Embraer announced an increase in the aircraft's cargo capacity to. At the 2011 Paris Air Show, Embraer announced plans to launch a stretched version of the C-390 focused on the civil market for freighters sometime around 2018. It estimated that the company would receive 200–250 orders over a 10-year period. To increase internal capacity, two plugs will be added fore and aft of the centre fuselage section, which would also provide a new side cargo door.
In April 2011, Embraer estimated that 695 military transport aircraft worldwide would need to be replaced in the following decade.
Partnerships
In August 2010, the defence ministers of Chile and Brazil signed an agreement for the Chilean aircraft company ENAER to join the C-390 industry team. That same month, Argentine Defence Minister Nilda Garré announced that Argentina through FAdeA, would participate in the construction programme. In September 2010, Colombia signed an agreement to participate in the C-390 programme. On 10 September 2010, the defense minister of Portugal signed an intentions letter to join the programme. In December 2011, Brazil and Portugal agreed to a defense partnership with Empresa de Engenharia Aeronáutica for developing the engineering data for the KC-390's components, which will be manufactured by Embraer's Portuguese subsidiary OGMA.In April 2012, the American aerospace giant Boeing and Embraer signed a cooperation agreement. Two months later, an agreement was signed by the two companies to collaborate on the development of the C-390, and possibly extending to sales as well. In June 2013, Boeing agreed to market the C-390 in the US, UK, and Middle East, building on the June 2012 MoU. In November 2019, it was announced that Boeing and Embraer were to form a new joint venture company to promote and develop new markets for the C-390 Millennium. This new company, Boeing EmbraerDefense, was to have its ownership divided between a 51% stake held by Embraer and 49% by Boeing. It was to begin operations following the granting of regulatory approvals and the satisfaction of closing conditions. However, in April 2020, Boeing terminated the planned joint ventures with Embraer.
Major subcontractors include Aero Vodochody for the rear fuselage section, BAE Systems for the fly-by-wire primary flight control system, ELEB for the landing gear, OGMA, involved in the design and manufacturing of the sponsons, including the central fuselage, and development of the landing gear, rear wing elevators, fuselage and part of the rudder with CEiiA, with Rockwell Collins for the avionics, cargo handling and aerial delivery system. Fábrica Argentina de Aviones supplies the tail cone, cargo door and landing gear doors. International Aero Engines supplies the V2500-E5 turbofans. Its use on the C-390 was its first military application.
On 25 April 2023, in a joint statement by Brazil and Portugal, it was announced that the KC-390 could be built or assembled in Portugal by OGMA for European customers along with the new A-29N.
Flight testing
It was decided to construct a pair of prototypes to participate in the test programme. On 21 October 2014, the first prototype rolled out from the Embraer subsidiary plant, Embraer Defense and Security, at Gavião Peixoto, São Paulo. On 3February 2015, the first prototype performed its maiden flight.In July 2015, the company announced a two-year delay in the flight test program, citing the devaluation of the Brazilian currency and government spending cuts. However, a second test flight took place at Gavião Peixoto on 26 October 2015. By February 2016, the first prototype had logged more than 100 hours of flight. Following the resumption of flight-testing, the manufacturer expected to certify the C-390 sometime in 2017 and begin deliveries in 2018. The eight months between test flights were used to conduct ground vibration tests to validate aeroelastic models, as well as avionics, mission, landing gear and electric and hydraulic flight control system testing. Embraer reported good availability for testing, sometimes conducting two flights per day. The aircraft was tested to the limits of speed, Mach number, and altitude, as well as all slats, flaps and landing gear positions.
In March 2016, the second prototype was completed. It conducted its first flight in April 2016. By then, Richard Aboulafia's Teal Group estimated the C-390's price to be around $50–55 million, which was $15 million below that of the competing Hercules.
On 17 October 2017, the first prototype made an uncommanded descent from 20,000 ft to 3,100 ft at 4,500 ft/min. In December 2017, as the two prototypes accumulated over 1,500 flight hours and laboratory testing over 40,000 hours, initial operating capability was reached, while full operational capability was expected in 2018. On 5May 2018, the first prototype ran off the runway during a ground test in Gaviao Peixoto, Brazil. The first production C-390, which was the third aircraft to be built including the prototypes, made its first flight on 6October 2018.
On 23 October 2018, the C-390 was issued with Brazilian civil type certification. By this point, the aircraft has cumulatively attained 1,900 flight hours during testing, while the first production aircraft was set to be delivered to the Brazilian Air Force in the first half of 2019 and should obtain military certification by the end of 2019. The third aircraft, originally slated for the first delivery, was instead redirected towards the certification efforts.
In February 2021, Embraer and the Brazilian Air Force dispatched a single KC-390 to the US to undergo testing under extreme cold conditions.