Sikorsky is aiming to start offering a new modular and readily swappable nose for the venerable H-60 family of helicopters within the next year or so. The noses will be made available on new-production H-60s, as well as be retrofittable to helicopters in service now. The ‘nose jobs’ will help operators relatively quickly reconfigure their H-60s for very different missions, from cargo-carrying to serving as gunships, as required. It also opens new avenues to integrating autonomous capabilities and other advanced functionality.
Our Howard Altman had a chance to speak with representatives from Sikorsky, now a subsidiary of Lockheed Martin, about the plans for the new nose for the H-60-series at the Association of the U.S. Army’s (AUSA) main annual convention today. This is part of a larger vision for keeping the design operationally relevant into the 2070s, which also includes uprated engines and increased total payload capacity. You can read more about the overall Black Hawk 2070 strategy here.
Of the different elements of Black Hawk 2070, “the nose is a good one, and it’s one that’s on a pretty accelerated timeline. Within the next, I would say, year or so, the nose will be available to be retrofitted or to be coming off the line,” Jason Wrigley, Sikorsky’s director of business development for Black Hawk, said. “We’ve gone through a design cycle with it.”
As it stands now, the new nose structure will offer roughly double the physical space of the standard nose on current-generation H-60s today.
“We’ve done the design. We then 3D-printed the noses, and we did that so that we can physically interact with it, because the whole point of this is for maintainability and access to be able to integrate these different sensors and comms gear,” he continued. “We’ve gotten some feedback from the engineers, from operators, from maintainers, and that goes back into the next cycle of the design.”
Exploring ways to optimize accessibility to areas of the new nose was a major focus of this ‘test print,’ according to Wrigley. Sikorsky has a scale model on the show floor at AUSA this week that highlights how the current design opens from the top, as seen below. Ensuring that it will be possible to keep any systems inside sufficiently cooled has also been an important design consideration already.
Overall, “we just are kind of confirming, can we reach everywhere we need to? What are the different configurations?” he added. There’s been “a lot of work with the [U.S.] Army around what do you envision potentially could go in here?”
“This is one of those cases also where our whole engineering team gets more comfortable. It’s not something where the Army came to us and said, ‘this is exactly what I want. Here’s my spec,'” he also noted. “It was more, ‘here’s what I want to achieve. Here’s what I want to be able to do.’ And so we went off and designed that.”
“I like to highlight this, because it’s part of the way we’re also changing the way we design and deliver the Blackhawk,” Wrigley added as an aside. “So we’re very much in a model-based environment.”
While Wrigley mentioned sensors and communications equipment as possible payloads to fit into that extra space initially when talking with us today, he made clear later on that these are just some of the potential options.
“It’s using the old term, but it’s open architecture, and so the whole point is whatever the mission requires” can go into these new extended noses, he explained. “There’s always a demand for real estate up front.”
It’s very true that more specialized variants of the H-60, such as the MH-60s operated by the U.S. Army’s elite 160th Special Operations Aviation Regiment, often have modified noses loaded with radars, other sensors, and additional systems. The new HH-60W Jolly Green II rescue helicopters for the U.S. Air Force are another prime example of this, and there are many more.
“There’s a big focus on open architecture and that ability to quickly plug-and-play,” Wrigley also told TWZ earlier this month in the context of the larger Black Hawk 2070 plan. “The new modular nose will change the look of the Black Hawk up front to provide even more space for equipment that will work directly with the new digital architecture.”
In terms of swapping out modular noses on individual helicopters, Wrigley said that it is still too early in the design process to know exactly how that would be done and how long it might take to do so in practice.
“Part of the design process is to also write up the documentation for the retrofit, but we don’t see this one as very invasive,” he explained.
It is not hard to imagine use cases for long-nosed H-60s, especially ones that can then be reconfigured between missions, and not just for the U.S. Army. As Wrigley already underscored, there is long-standing demand for H-60s with longer and larger noses to accommodate additional mission systems. Modular noses, in general, have been becoming more and more common in aviation design for some time now.
The ability to readily swap modular noses could also allow operators of even relatively small H-60 fleets to gain a valuable new degree of multi-mission capability. As one example, cargo-carrying helicopters could be converted into gunships, and back again, as required, using a small common pool of noses with the requisite sensors, laser designators, and other equipment. All of this could offer cost benefits when it comes to sustainment and logistics, as well as added operational flexibility.
The long-nosed Black Hawk model on display at AUSA is notably configured as a gunship. Sikorsky has also talked previously about leveraging the new nose to reconfigure H-60s for search and rescue, airborne drone control, and other missions.
Just being able to install a radar for one series of missions, and then quickly switch over to an electro-optical wide-area surveillance system or another kind of sensor for the next run of sorties, would bring new adaptability to the already very flexible Black Hawk. Defensive systems could also be readily swapped from aircraft to aircraft, as well as more quickly upgraded, as needed.
The modular nose also opens the door to a new way to integrate advanced capabilities, including autonomy packages, which Wrigley said is also driving demand for more space at the front end of the helicopter. Sikorsky has been developing various tiers of autonomous capabilities for the H-60 family for years now, including artificial intelligence-driven ‘copilots’ designed just to help reduce the workload of human crew members and increase safety margins. Autonomous flight capabilities require additional sensors, such as LIDAR and cameras, to help with navigation and to provide additional situational awareness. At least some of those components could be hosted within new modular noses.
At the same time, integrating higher degrees of autonomy could require more substantial modification. Sikorsky is now developing a fully uncrewed version of the H-60, and has been doing so with an eye toward converting older Black Hawks to this configuration as they are retired from service, as you can read more about here.
In line with the Black Hawk 2070 vision, the modular noses could be part of a broader equation for modernizing existing H-60 fleets, as well.
“In our conversations with the Army, I think they’ve been using a phrase that they call targeted modernization,” Wrigley told us, speaking more generally. “There’s a daunting task that says there’s 1,000-1,500 Black Hawks in inventory. If you literally tried to upgrade every one of them, it’s a very expensive proposition, and it probably takes a long time.”
“I don’t think that’s the way they’re thinking about it. I think they’re thinking about it more on a battalion basis or a unit basis,” he continued. “Like, what’s the mission, and maybe certain Black Hawks get upgraded with autonomy, and other Black Hawks get upgraded with sort of the expanded launched effects capability, the engine, the structural upgrades, the [stub] wings, stuff like that.”
“Maybe some of them become ‘Superhawks’ or whatever, [and] get the whole package,” he added.
There is certainly still work to be done on the development of the new modular nose and then actually integrating it onto the H-60 platform. At the same time, Sikorsky clearly already sees demand for this new feature, which could lead to a breadth of new opportunities for new and old helicopters in the H-60 line.
Contact the author: joe@twz.com
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