Sikorsky Ramps Up Production of New S-92A+ Helicopter Variant

Sikorsky is set to commence production of the newest iteration of its leading heavy helicopter, the S-92A+, signalling the next phase for one of the most extensively utilised large commercial rotorcraft globally.

The aircraft will be manufactured and assembled at Sikorsky facilities in Stratford, Connecticut and Owego, New York, with the first production batch destined for a new head-of-state transport customer. The program also anticipates further orders from government and offshore energy operators as demand for high-capability, long-range helicopters continues to grow.

According to Sikorsky, the company is building additional production capacity to meet anticipated global demand across several mission sectors, including executive transport, offshore oil and gas support, search and rescue (SAR), cargo operations and military roles.

The new S-92A+ variant builds on the reputation of the long-serving Sikorsky S-92, which has become one of the most trusted heavy helicopters in commercial service since its introduction in the early 2000s.

Rich Benton, Sikorsky vice president and general manager, said the upgrade reflects the company’s long-term strategy to modernise the S-92 fleet while preparing for increased global demand. “The S-92A+ helicopter is another example of how we are modernising the fleet and transforming for the future,” Benton said. “We are building in surge capacity to meet expected demand. The S-92 remains the aircraft of choice for head-of-state, offshore energy and search and rescue operators who need a helicopter capable of long-range missions in any weather condition.”

Sikorsky currently plans to assemble five S-92A+ helicopters in the initial production run. Two of those aircraft will go to a newly confirmed 14th nation operating the S-92 in a head-of-state role, while the remaining three aircraft are expected to support additional anticipated orders.

The manufacturer says it can scale production to as many as 12 aircraft per year, depending on market demand.

Manufacturing responsibilities will be split between Sikorsky’s established production centres. At the company’s Stratford headquarters, technicians will build key dynamic components, including the helicopter’s main gearbox, rotor blades and drivetrain systems. These components form the heart of the aircraft’s mechanical architecture and are critical to its heavy-lift capability.

Final assembly will take place in Owego, New York, where Sikorsky has extensive experience building aircraft derived from the S-92 platform. The facility previously assembled 23 U.S. presidential helicopters developed from the S-92 airframe for the Sikorsky VH-92 Patriot program.

The company also delivered two S-92A helicopters in 2025 to head-of-state customers in Asia and the Middle East, demonstrating continued demand in the VIP and government transport markets.

While the S-92 already enjoys a reputation for reliability and safety, the new S-92A+ configuration introduces several important technical improvements designed to enhance performance, endurance and operational efficiency. Central to the upgrade is the Phase IV main gearbox, which Sikorsky describes as the most advanced gearbox currently available in the commercial helicopter sector.

The gearbox is now undergoing its final 200 hours of endurance testing, a key milestone before full certification. One of the major improvements is its 6,000-hour minimum operating lifecycle, significantly extending the interval between major overhauls. This improvement is expected to reduce maintenance downtime and operating costs for commercial operators. The gearbox also incorporates auxiliary lubrication, allowing the helicopter to complete a flight safely even in the event of primary oil pressure loss, an important safety feature for aircraft operating long distances offshore or over remote terrain.

Power for the S-92A+ comes from upgraded General Electric CT7-8A6 engines, which deliver increased shaft horsepower compared with earlier versions.

The additional engine power improves performance in hot-and-high conditions, a critical requirement for operations in regions such as the Middle East, Africa and parts of Asia where high temperatures and elevation can severely affect aircraft performance.

Combined with structural strengthening of the airframe, the increased power allows the S-92A+ to operate at a maximum gross weight of 27,700 pounds, enabling operators to carry approximately 1,200 pounds more payload or fuel. The helicopter’s external sling-load capability has also been significantly enhanced, expanding its usefulness for cargo operations, disaster relief and firefighting missions.

Importantly for current customers, Sikorsky has designed the S-92A+ improvements to be retrofit compatible. Existing S-92A aircraft can be upgraded to the new standard through a retrofit kit that includes the Phase IV gearbox and the option of upgraded engines. This approach allows operators to extend the life and capability of their current fleets without purchasing entirely new aircraft.

With more than 300 S-92 helicopters delivered worldwide, the platform has accumulated millions of flight hours across demanding roles ranging from North Sea offshore transport to long-range search and rescue missions.

The arrival of the S-92A+ suggests Sikorsky is committed to keeping the type relevant for decades to come, an encouraging sign for operators who rely on the helicopter’s unique combination of range, payload and reliability.