[Militech] Helicopter Blade Technology Learned Despite French Rebuff Now Drives 'K-Defense Industry'

Successfully Developed Core Helicopter Blades In-House
Inspired by the Words, "It Took Three Months to Master Proper Bungeoppang"

After experiencing the Korean War, the South Korean military found itself in urgent need of attack helicopters. This was because they were the only effective means to counter North Korea's tank forces. The aircraft that caught the military's attention was the '500MD.' Equipped with M-134 machine guns, 70mm rocket launchers, and TOW anti-tank missiles, it was capable of effectively deterring North Korean tanks. The U.S. military operated the same helicopter under the name 'OH-6' as a reconnaissance helicopter. Over time, however, the aircraft became severely outdated. There are two main methods of flying an aircraft: visual flight rules (VFR) and instrument flight rules (IFR). The 500MD could only operate under VFR, relying solely on visual cues. As a result, crashes were frequent.

The first domestic helicopter, the Korean Utility Helicopter (KUH-1) 'Surion' (Photo by Korea Aerospace Industries)

The South Korean military needed a helicopter to replace the 500MD, which had been in service for over 50 years. This led to the launch of the Korean Helicopter Program (KHP) in 1995. However, the project faced obstacles from the outset. At the end of 1997, the IMF financial crisis erupted, and the program was entirely canceled. It was not until after 2001 that discussions to revive the project resumed. In September 2003, the KHP, which aimed to develop both utility and attack helicopters simultaneously, was designated as a national project. Korea Aerospace Industries (KAI) invested 1.3 trillion won over 73 months (about six years) to develop the nation's first domestic helicopter, the Korean Utility Helicopter (KUH-1) 'Surion.' As a result, South Korea became the 11th country in the world to produce helicopters.

Successfully Developed Core Helicopter Blades In-House

The development process was far from easy. The pinnacle of helicopter technology lies in the 'composite blades (rotor blades).' At the time of Surion's development, KAI had no technology or experience with composite blades. Although KAI requested cooperation from its technology partner Eurocopter (EC), the company was reluctant to transfer its technology. Eurocopter even retrieved CD materials obtained during business meetings at the airport, delayed progress by claiming they needed to translate French documents into English, and provided incomplete data. It was akin to needing technology for a luxury sedan but only being taught about compact cars. The researchers were frustrated. What gave them renewed courage was an encounter with a fish-shaped pastry (Bungeoppang) vendor in front of Sacheon Bus Terminal. The vendor said it took him three months to perfect a pastry that didn't leak sweet red bean filling, inspiring the researchers not to give up. Motivated by this, they succeeded in developing the blades in-house. KAI has since filed patents for its blade manufacturing know-how in preparation for exports.

KAI Assembly Plant Capable of Producing 36 Units Annually

Since then, the Surion has evolved into 10 different variants, including amphibious assault, medevac, coast guard, firefighting, and forestry helicopters. KAI developed the Marineon, an amphibious assault helicopter (MUH) mainly operated by the Marine Corps Aviation Group, and in January this year, completed test flights of the Marine Attack Helicopter (MAH). The MAH will provide cover missions during Marineon assaults on enemy territory and deliver fire support upon request from ground forces. KAI also developed the Light Armed Helicopter (LAH), a domestically produced helicopter intended to replace the Army’s 500MD and Cobra attack helicopters (AH-1S). As of last year, three LAH units had been mass-produced, with plans to supply a total of around 170 units to the Army. The KAI assembly plant is expected to have the capacity to assemble up to 36 helicopters annually.

The main gearbox of the LAH supplied to the military is assembled in-house. While the main gearbox is typically assembled using components purchased from foreign original manufacturers, KAI now manufactures it domestically. Producing the main gearbox in-house makes South Korea the fifth country in the world to do so, following the United States, the United Kingdom, France, and Italy. Blade production is handled by robots-a world first-even advanced overseas companies have not succeeded in this. KAI is also considering equipping helicopters with unmanned aerial vehicles (UAVs) in the future. The plan is to launch a total of four UAVs, two from each side of the fuselage, which will automatically deploy their wings and fly. One of these UAVs can perform a kamikaze-style attack by crashing into a target and detonating.

A KAI official explained, "The LAH can carry UAVs, enabling manned-unmanned teaming operations, so it can perform missions on par with Apache helicopters." For pilot convenience, the LAH is equipped with an integrated map and electronic computer to help navigate anywhere nationwide, an automatic flight control system, a weapon integration system, and a target acquisition designator to detect targets ahead. Among similar attack helicopters, the LAH is the only one equipped with a joint tactical data link system that enables real-time sharing of battlefield information.

Russian Helicopters Grounded Due to Ukraine War

In addition, the Surion has been developed into various derivative models for police, firefighting, forestry, and coast guard use. Interest in these helicopters has grown domestically following Russia's invasion of Ukraine. In 1992, the South Korean government provided $1.47 billion in loans to the former Soviet Union for economic cooperation. When Russia was unable to repay the debt, it was settled with military equipment instead-a deal known as the 'Bulgeom Project.' Through this project, a total of 43 Russian-made Ka-32 helicopters were introduced into South Korea, making it the second-largest operator of Ka-32s after Russia. However, as the war between Ukraine and Russia, which began in 2022, has dragged on, Russian helicopters have become a liability. Russia designated South Korea as an unfriendly country for participating in international sanctions and banned exports. As a result, the supply of parts has been cut off, and currently, 14 Ka-32 helicopters are grounded.

Potential to Export 1,000 Units Targeting the Aging Helicopter Market

KAI expects that helicopter exports will lead the 'K-Defense Industry' in the future. According to global market research firm Fortune Business Insights, the global helicopter market is expanding rapidly. Until last year, the market was valued at $74.52 billion (108.4936 trillion won), but by 2032, it is expected to grow to $97.13 billion (141.3338 trillion won). There are currently a total of 55,656 helicopters worldwide (23,283 military and 32,372 civilian). KAI believes it could export up to 1,000 helicopters by targeting the aging helicopter market. According to the Korea Institute for Industrial Economics and Trade, exporting around 400 helicopters would create 90,000 jobs and generate 29.76 trillion won in economic benefits. Given that after-sales support projects typically generate about twice the sales revenue of the initial sale, the economic impact is expected to be even greater.

A KAI official stated, "Exporting domestically produced helicopters will also enhance the nation's prestige," adding, "As a helicopter-developing country, South Korea will gain true recognition for its value not only in the domestic defense industry but also through exports."