In a groundbreaking feat of engineering, the U.S. Air Force has successfully combined two severely damaged F-35 fighter jets into a single operational aircraft, dubbed the “Franken Jet.” This innovative project, which took over two years and cost $11.7 million, represents a significant leap in military repair capabilities and underscores the importance of preserving these high-value assets.

The F-35 Lightning II, known for its stealth and advanced technology, has been a centerpiece of U.S. military operations, with over 1,150 units delivered worldwide. However, the high cost of these jets—exceeding $50 million each—makes any loss a substantial blow to national defense budgets. The Franken Jet was 𝐛𝐨𝐫𝐧 out of necessity after two F-35s, designated AF27 and AF211, were rendered inoperable due to catastrophic incidents.

AF27 suffered a devastating engine fire in 2014, while AF211 was damaged during a landing mishap in 2020. The innovative repair process involved grafting the rear section of AF211 onto the undamaged nose of AF27, showcasing a novel approach to aircraft recovery that could revolutionize future military repair strategies.

Lead mechanical engineer Scott Taylor emphasized the historic nature of this project, noting that while the concept of combining damaged airframes had been discussed since January 2020, this is the first successful execution of such a plan. The aircraft’s first flight, conducted on January 24, 2025, demonstrated performance on par with newly manufactured jets, proving the viability of this ambitious repair method.

With the Franken Jet now fully operational and ready for deployment, the U.S. Air Force not only saved $63 million compared to purchasing a new aircraft but also set a precedent for future repairs of advanced military aircraft. This remarkable achievement highlights the ingenuity and resourcefulness of the U.S. military as it continues to adapt and innovate in the face of challenges.