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AH-64E Program

AH-64E Remanufacture (formerly known as AB3A) schedule encompasses a 12-year EMD phase which began with a risk reduction effort from May 2005 to July 2006. This effort was followed by the current development effort which began in July 2006 and will continue through September 2019. Production started in 2010 and will continue through 2025.

On June 28, 2006, the Defense Acquisition Executive (DAE) conducted a successful Milestone (MS) B review of the AH-64E program. As a result, the DAE signed an Acquisition Decision Memorandum (ADM), dated July 10, 2006, approving MS B, authorizing the AH-64E program to enter System Development and Demonstration (SDD) and designating it as an Acquisition Category (ACAT) ID program. On July 14, 2006, the Apache Project Manager (PM) awarded an SDD contract to the Boeing Company to begin the development effort for AH-64E. A follow-on ADM was approved on March 7, 2007 authorizing an LRIP quantity of 59 aircraft and granting Army authority to procure long-lead items beginning in FY 2009. The APB schedule milestones established for the Preliminary Design Review and the Critical Design Review were successfully completed on April 19, 2007 and January 30, 2008 respectively. The Limited User Test was successfully executed in November 2009.

The PM was directed in to increase total procurement quantity by 56 aircraft. These 56 aircraft were Apache AH-64E New Build aircraft included in the FY 2011 PB at a total of $2.6 billion. This change was implemented to support an increase to the training base capacity and to establish a new heavy combat aviation brigade in the active component. The baseline program was a remanufacture production program. These additional aircraft procurements would be Apache AH-64E New Build aircraft at a unit cost significantly higher than the remanufacture unit cost. The addition of the Apache AH-64E New Build aircraft along with minor fact-of-life changes to the program since the beginning of the RDT&E phase caused a Nunn-McCurdy unit cost breach to the APUC which was reflected in the December 2009 SAR. The DAE supported a rapid Nunn-McCurdy process which was completed June 1, 2010 with an ADM certifying the program to move forward to MS C and separating the program into two Major Defense Acquisition Programs for cost and reporting purposes (Apache AH-64E Remanufacture and Apache AH-64E New Build).

A successful MS C Defense Acquisition Board (DAB) was completed on September 27, 2010. The Apache AH-64E DAB allowed the move into LRIP and advance procurement actions for Full Rate Production (FRP). An LRIP contract was awarded on October 22, 2010 procuring a total of 51 remanufactured AH-64E aircraft. The first Apache AH-64E Remanufacture production delivery occurred October 24, 2011 with a formal roll out ceremony held November 2, 2011. The Initial Operational Test and Evaluation for the Apache AH-64E Remanufacture production aircraft was completed April 2012. A successful DAB was held on August 16, 2012 which approved FRP for the Apache AH-64E Remanufacture program and authorized up to 12 LRIP aircraft for the Apache AH-64E New Build program in FY 2013. The DAE issued an ADM that approved the designation of the Apache AH-64E Remanufacture and Apache AH-64E New Build programs as ACAT IC after approval of the AH-64E Remanufacture APB. The ADM also stated that once the AH-64E New Build program was designated as ACAT IC, the Army Acquisition Executive (AAE) would be responsible for the Apache AH-64E New Build APB and the subsequent Apache AH-64E New Build FRP decision as the Milestone Decision Authority. The APB was approved by the DAE on November 26, 2012. The pache AH-64E New Build ADM was approved by the AAE on March 11, 2013 and authorized FRP for the Apache AH-64E New Build program.

The Apache PM's Office has breached the APB threshold for procurement cost for the AH-64E Remanufacture program, the APUC and PAUC APB 10 percent threshold. This cost divergence is largely due to an updated Program Office Estimate (POE) that includes the Army decision to move the Recapitalization costs ($378M) for Airframe and Sensors to the AH-64E Remanufacture funding line from the AH-64 Modifications Aircraft Procurement, Army funding line for years FY 2015 through FY 2026. This cost was not previously included in the Office of the Secretary of Defense Cost Analysis and Program Evaluation (CAPE) Independent Cost Estimate (ICE) when the APB was established. Also not captured in the CAPE ICE are the “Fact of Life” changes that are having a compounding affect on the current POE. These changes include FY 2013 Congressional reductions ($50M), FY 2013 Sequestration ($34M), an FY 2014 Army adjustment ($100M), and the current FY 2015 PB changes ($175M). These changes significantly reduce procurement quantities below the minimum sustainment rate of 48 per annum for the AH-64E production line which significantly increases unit costs.

The Defense Acquisition Board decision regarding full-rate production for the Apache Block III helicopter program was announced 24 October 2012, by Army officials at a briefing in Washington, DC. Additionally, Apache project manager Col. Jeffrey Hager confirmed that the Apache Block III was being re-designated as an AH-64E model. According to the Apache Project Office, the Defense Acquisition Board, or DAB, granted approval for full-rate production, or FRP, in August and the Air Force communicated the model designation change in a September 2012 memo to the Army. Actions were under way to begin implementation of the E model designation for subsequent use by the military and industry.

"The DAB's decision really secured Apache production for the next several years," Hager said. "We've got fiscal requirements, but securing that production through a full-rate production decision was just huge for this program. It's probably the single largest decision that we've had since Block I's and Block II's went into production. It's that monumental."

One of the other key components, Hager said, that resulted in the DAB decision is the fact that the Block III had been designated an ACAT C program. "We're no longer a D program and therefore don't need DOD oversight. Our Army acquisition executive, Ms. Heidi Shyu, is in charge of the Apache program and the development production that we have for Block III as we go forward from this point. So that was a big designation for us," Hager said.

The designation of the E model, he added, accurately recognizes the aircraft's advancements including an Improved Drive System, increased engine capabilities, technologically advanced composite main rotor blades and sensor enhancements. "At the end of the day, the only real measure of how well a system is performing falls to the user and how easy or difficult the aircraft is to maintain," said Col. John Lynch, Attack/Reconnaissance TRADOC capabilities manager. "Basically, the Block III exceeded expectations that were laid out on the sustainment side."

The improved drive system of the AH-64E provides the pilot with an exceptional power margin between power required and power available, and is capable of carrying 2,500 pounds more than its predecessor, the AH-64D Model. This translates into a safety margin for the crew and increased combat capabilities for the ground force commander. The E Model can take more fuel and ammo to the fight, get there faster, and stay there longer.

Upgrades to the aircraft over previous models include advanced rotor blades and significantly increased aircraft handling, performance and agility at higher altitudes. Situational awareness is enhanced with electro-optical and infrared sensors for the operational benefit of aviators and battlefield commanders.

In 2011, Boeing delivered the first AH-64D Apache Block III multirole attack helicopter to the Army. Block III brought superior flight performance and increased networked communications capabilities. In 2012, Boeing received all-new fuselages for the first AH-64E helicopters, incorporating a variety of small but important modifications to accommodate AH-64E configuration changes, such as enhancements to the extended forward avionics bays and slots for new electronics. More than 100 AH-64Es had been produced as of October 2014.

First delivered in October 2011, Apache Block III helicopters are in production at the Boeing Company in Mesa, Ariz. Since January 2013, 1-229th Attack Reconnaissance Battalion, nicknamed Tiger Sharks, has received eight of the "Echo" model Apaches and was scheduled to complete its fielding by the end of April 2013 with a total of 24. The 1-229th Attack Reconnaissance Battalion, the Army's first unit equipped with AH-64Es, deployed from Joint Base Lewis-McCord with their AH-64Es in March 2014to Afghanistan.

The Echo model has already proved its worth. As good as the AH-64D is as the world's premier attack helicopter, the AH-64E has proven even better during home station training, FOT&E, as well deployed to Afghanistan providing increased capabilities for the supported maneuver unit.

The AH-64E Lot 4 capability enhancements, scheduled for delivery in 2017, include external crashworthy fuel tanks and software upgrades. The bulk of the capability, though, comes with the integration of the Link 16 tactical data link. Link 16, a secure joint, wireless network-in-the-sky, allows AH-64E crews to disseminate critical information in real time to other aircraft, as well as ground and maritime platforms.

All of these Lot 4 capabilities are in addition to the already fielded Lot 1-3 AH-64E models, which have improved digital connectivity, enhanced communication systems, more powerful engines, an upgraded transmission to accommodate the increase in power, capability to control unmanned aircraft systems, new composite main rotor blades and a fully instrumented flight rules qualified aircraft.

By December 2013, 51 LRIP Apache AH-64E Remanufacture aircraft have been delivered. Apache AH-64E First Unit Equipped and IOC milestones were successfully reached in May 2013 and November 2013 respectively, as planned. FRP contract negotiations are complete for both the Apache AH-64E Remanufacture and Apache AH-64E New Build Programs, and the first FRP Remanufacture Apache AH-64E was delivered in March 2014.

In December 2013, the 1st Battalion, 229th Aviation Regiment (1-229) Attack Reconnaissance Battalion (ARB) from Joint Base Fort Lewis-McCord, Washington, conducted a pre-deployment validation with the Combat Aviation Brigade (CAB) commanders and United States Army Aviation and Missile Life Cycle Management Command (AMCOM) leaders to discuss unit readiness and logistic shortfalls for the initial AH-64 E-model deployment. The 1-229th leadership expressed readiness concerns reference 89 DLA National Item Identification Numbers (NIINs) as potential mission “showstoppers” if the NIINs were not adequately stocked prior to the March 2014 deployment.

All items were not provisioned in proper quantities prior to Low Rate Initial Production (LRIP) and the initial delivery of aircraft to the 1-229th, as the first unit equipped. Additionally, maintenance units at the 1-229th (Ft. Lewis) and the 1-25th (Ft. Carson) were consuming material at a higher rate than the provisioned quantities, resulting in new procurement requirements as the initial deployment date approached.

The Defense Logistics Agency Aviation, Customer Operations Directorate, Army Customer Facing Division is the link between DLA and the Army by ensuring military service priorities and initiatives remain in the forefront and contribute towards aircraft availability and unit readiness. The AH-64 Weapon Systems Support Team played a central role in providing timely sustainment support to AH-64E Apache helicopters deployed to Afghanistan from March to November 2014.

On April 07, 2016 Boeing Co., Mesa, Arizona, was awarded a $922,628,257 modification (PZ0011) to contract W58RGZ-14-C-0018 for 117 AH-64E remanufactured Apache helicopters. Work will be performed in Mesa, Arizona, with an estimated completion date of May 31, 2018. Fiscal 2015 and 2016 other procurement (Army) funds in the amount of $922,628,257 were obligated at the time of the award. Army Contracting Command, Redstone Arsenal, Alabama, is the contracting activity.

Boeing would remanufacture 117 AH-64D Apaches to the new, more capable AH-64E model. The agreement, which also includes the acquisition of Longbow Crew Trainers, logistical support and spares, carries a total contract value of about $1.5 billion. “The AH-64E Apache continues to meet the requirements of aviators, battlefield commanders and soldiers deployed on missions worldwide,” said U.S. Army Apache Project Manager, Col. Jeff Hager. “The Army, Boeing and Team Apache suppliers continue a valuable collaboration that ensures soldiers have the latest technologies to succeed in defending freedom with this outstanding weapons system.”

The agreement modifies an existing contact among Boeing and the Army for the full-rate production of lots 5 and 6 Apache helicopters. The Army will return 117 AH-64D Apaches to Boeing’s Mesa, Ariz. production center to be remanufactured into the AH-64E configuration. The Army followed a similar model when the AH-64A Apaches were remanufactured into AH-64Ds.

The U.S. Army had stated it planned to acquire 690 AH-64E Apaches, 290 of which were under contract with the 2016 award.

On March 16, 2017 Boeing and the US government signed a five-year, $3.4 billion contract through which the Army, and Saudi Arabia, will acquire the latest Apache attack helicopter at a significant savings to taxpayers. This was the first multi-year agreement for the Apache “E” variant. The Army will receive 244 remanufactured Apaches while 24 new ones will go to the international customer.

"This agreement is great news for our Army, our soldiers, the American taxpayers, our industry partners and numerous international partners,” said U.S. Army Col. Joseph Hoecherl, the Apache project manager. “It is a direct result of the professional dedication and diligent efforts by government and industry teammates to provide the much needed capabilities of the world's best attack helicopter - the AH-64E Apache - at a fair and affordable price that results in year over year savings to the taxpayer. In the hands of our trained U.S. soldiers, the Apache's technologies and resulting capabilities are essential to Army operations around the globe."

Boeing builds the Apache in Mesa, Ariz. Deliveries of the “E” model began in October 2011. Seven customers outside the US had ordered this variant. Including this latest version, the US and 15 other countries had relied on the Apache during the past three decades.

With 500 AH-64E Apaches in service with the United States Army and defense forces around the world by April 2020, the ‘Echo’ model provides enhanced performance; joint digital interoperability; situational awareness and survivability with reduced operational and support costs. First delivered in 2011, the AH-64E has been used in combat operations and peacekeeping efforts. Planned modernization of this multi-role combat helicopter ensures it is ready to fulfill operational requirements globally.

Boeing will build 184 AH-64E Apaches for the U.S. Army and international customers, including the first Apaches for Australia. This $1.9 billion award March 17, 2023 brought the total current funded value of the contract to $2.1 billion, and has the potential to increase to more than $3.8 billion with future obligations. The U.S. Army will receive 115 remanufactured Apaches, with an additional 15 Apaches to be procured as options, ensuring significant savings to taxpayers. The additional 54 aircraft will be delivered to partner nations as part of Foreign Military Sales.

This award comes on the heels of the U.S. Army’s Apache fleet surpassing five million flight hours, a milestone proving the AH-64 is the most capable, reliable and versatile attack helicopter.

Under the first multi-year contract, signed in 2017, Boeing delivered 244 remanufactured Apaches to the Army and 24 new-build aircraft to an international customer. The AH-64E, built at the Boeing site in Mesa, Ariz., is the most advanced multirole combat helicopter in the world. There are more than 1,275 Apaches currently in operation around the world.

L3 Technologies (NYSE:LLL) announced 30 October 2914 that it had received a production contract for multiple awards totaling $97 million in support of the U.S. Army’s Apache Manned/Unmanned Teaming – eXpanded Capabilities (MUMT-X) helicopter program. By enabling communications and data teaming between manned and unmanned aircraft, MUMT-X provides the Apache AH-64E with a transformational warfighting capability that is significantly more robust, lighter and less expensive than the original Unmanned Aircraft System (UAS) control system. This award follows the successful completion of a 2015 MUMT-X communications upgrade contract in which L3 delivered state-of-the-art systems for high-speed transmissions of wideband video and data.

MUMT effectiveness for Version 4 and Version 6 units was limited during 2019 FOT&E. Interoperability and video sharing between AH-64E Apaches, unmanned aircraft systems, and ground stations is complicated and requires exacting pre-mission coordination of technical information across multiple organizations and systems. Aircraft interfaces, employment concepts, procedures, and documentation are not mature and contributed to the lack of interoperability between AH-64E aircraft and unmanned aircraft systems.

L3Harris Technologies (NYSE:LHX) was selected in 2021 by the U.S. Army to deliver advanced systems that will provide secure communications between manned and unmanned aircraft and ground forces. L3Harris is the only company providing Manned-Unmanned Teaming (MUMT) Airborne Data Link Systems for the Army’s AH-64 Apache attack helicopters, having delivered 256 systems to date. The systems allow forces to share real-time, full-motion video and data between Apache aircraft and unmanned aerial systems (UAS), such as the Army's Shadow and Grey Eagle aircraft, and integrated battlefield networks, enhancing decision making and mission effectiveness.

L3Harris' MUMT solution offers major advancements in resilient and protected networks and high data rates, leveraging a modular open standards system. In addition to receiving high-bandwidth ISR video from UAS, Apache crews can assume control of autonomous aircraft and their payloads. “The MUMT system provides a unique capability for new warfighting strategies and tactics, combining multiple assets and platforms for multi domain use," said Brendan O’Connell, President, Broadband Communication Systems, L3Harris. "Adding new MUMT capability to the Apache fleet will provide greater situational awareness and combat effectiveness across the battlefield."

By October 2023 the newest version of the AH-64E Apache was successfully flown with an upgraded capabilities suite as Boeing continued to modernize the platform. The upgraded E-model Apache, known as Version 6.5, or V6.5, is the next configuration of the world’s premier attack helicopter. “We saw our hard work come to life with this first flight,” said Christina Upah, vice president of Attack Helicopter Programs and senior Boeing Mesa site executive. “These enhancements will take the E-model Apache to the next level in terms of capabilities, ensuring Apaches continue to dominate future battlefields.”

V6.5, awarded by the U.S. Department of Defense in December 2021, includes software updates enhancing capabilities and improving the pilot interface. Some of those enhancements include:

• Optimized route and attack planning
• Enhanced Link 16 features
• Integration of an Open Systems Interface, setting the stage for Modular Open Systems Approach for maximum interoperability, faster integration and advanced capabilities fielding.

“We’re very excited about the ongoing development of the V6.5 software as it paves the way for Apache modernization,” Col. John (Jay) Maher, U.S. Army Apache project manager, said. “V6.5 aligns the entire E model fleet under the same software, streamlining training and maintenance while providing a pathway for sensor/capability parity, and enables the Army to address mandates and critical technologies. Ensuring relevance into the future is a top priority.”

Building onto V6.5, the company is working with the U.S. Army to integrate the Improved Turbine Engine (ITE). The engine, a General Electric Aerospace T901, will offer improvements in reach, available power, time on station and fuel efficiency, as well as sustainment improvements like health and usage monitoring, maintenance and engine lifespan.