In-depth analysis of the real cost of an hour of flight time for the F-35A, including maintenance, spare parts, training, and logistical support.

The F-35A, the conventional takeoff and landing version of the F-35 Lightning II program, is often presented as a fifth-generation fighter jet with advanced capabilities. However, beyond its operational performance, its operating costs raise many questions. While the initial purchase price is already substantial, the expenses associated with each flight hour, taking into account indirect costs such as maintenance, spare parts, training, and logistical support, represent a major challenge for the armed forces. This article provides a detailed analysis of these costs in order to better understand the financial implications of using the F-35A.

The direct cost per flight hour of the F-35A

The direct cost per flight hour of the F-35A is currently estimated at US$42,000, or approximately €39,500. This figure, published by the US Department of Defense for fiscal year 2020, corresponds to the expenses directly associated with operating the aircraft. These costs include fuel, routine maintenance, technical consumables, immediate support labor, and minor repairs carried out between operational missions. They exclude initial investments, training, infrastructure, and the long-term replacement of major components.

Fuel represents a significant portion of this cost. The F-35A consumes an average of 5,600 liters per flight hour, or approximately 4,400 kg of JP-8 fuel. At an average price of $0.8 per liter, this corresponds to approximately $4,480 per hour for fuel alone. Routine maintenance, including scheduled and unscheduled inspections, requires highly qualified personnel and the use of proprietary tools. Technicians must be certified on complex systems such as the AN/APG-81 AESA radar or the AN/ASQ-239 electronic warfare suite, which entails high salary costs.

In comparison, an F-16C/D has a direct cost of approximately $25,400 per hour, a difference of more than $14,000. This increase is linked to the greater sophistication of the systems on board the F-35A, its dependence on automated diagnostics (ALIS and then ODIN) and operational availability requirements that increase the frequency and rigor of maintenance.

This estimate varies depending on the annual utilization rate. A squadron flying 300 hours per aircraft will amortize certain fixed costs better than a more sedentary squadron. However, even when optimized, the direct cost of the F-35A remains one of the highest for a Western combat aircraft in active service.

Indirect costs: maintenance, spare parts, training, and logistical support

The indirect costs associated with the F-35A far exceed those of other combat aircraft. They include heavy maintenance, proprietary spare parts, specialized training for crews and technicians, and complex logistical support that is costly to maintain over the long term.

The extensive maintenance required for the F-35A cannot be carried out in conventional hangars. The aircraft requires facilities equipped with environmental control systems, calibrated lifting equipment, and integrated automated diagnostic systems (ODIN, replacing the former ALIS system). In addition, each operation must often be validated via centralized digital procedures, lengthening response times and requiring a high level of technical expertise. This translates into a significant workload for ground crews and an estimated average annual indirect maintenance cost of between €1.5 million and €2 million per aircraft.

Spare parts, nearly 70% of which are proprietary and manufactured only by Lockheed Martin-approved suppliers, create industrial dependency and very high unit costs. For example, a main landing gear costs nearly $180,000. Some critical parts, such as sensor modules, cost more than $500,000 each.

Training is also a major indirect cost. Each pilot must undergo several hundred hours of training, much of it in high-fidelity simulators, which cost several million dollars to purchase and tens of thousands of dollars per year to maintain. Technicians must undergo lengthy certification training, with frequent refresher courses.

Finally, logistical support, including the delivery chain, maintenance tracking software, rotating parts, and inter-service logistics, represents an estimated ongoing cost of more than $10 million per year for a squadron of 12 F-35As. These costs, which are not included in the list price, significantly increase the F-35A budget over its entire operational life.

Comparison with other fighter jets

The operating cost of the F-35A differs significantly from that of other fighter jets currently in service. For example, the F/A-18E/F Super Hornet, used by the US Navy, has a cost per flight hour of approximately US$30,400, or nearly €28,500. The Rafale, developed by Dassault Aviation for the French armed forces, remains more economical, with an estimated hourly cost of €20,000, including maintenance and fuel.

This difference can be explained primarily by the technological density of the F-35A. It features multi-spectral sensors, real-time data fusion, passive stealth, and a comprehensive digital human-machine interface. These capabilities, while operationally relevant, involve complex systems that are difficult to maintain, with specific spare parts that are often unavailable on the open market, driving up costs.

In addition, the F-35A’s maintenance cycle is more restrictive. While a Rafale or Super Hornet can perform missions with less frequent intermediate inspections, the F-35A requires regular checks, even on subsystems that are not mechanically stressed. This rigor stems from the integrated architecture and the high number of sensors that need to be calibrated, diagnosed, and even replaced preventively.

Another major factor is the projected service life. The F-35A is expected to remain in service until 2088, compared with 2040 to 2050 for the Super Hornet and the Rafale. This means that its total cost of ownership must include ongoing modernization expenses, particularly to maintain its superiority over evolving enemy systems.

Thus, although the F-35A budget seems disproportionate in the short term, it reflects a strategic ambition spanning several decades. On the other hand, armed forces with less expensive aircraft have more flexibility to spread their investments over the medium term, with more modular fleets and lower operating costs.

Budgetary and strategic implications

The operation of the F-35A represents a considerable budgetary burden for the air forces that have chosen it. With a unit acquisition cost of around €89 million and an annual operating cost of over €5 million per aircraft, maintaining an operational squadron becomes a complex budgetary balancing act. A fleet of 24 F-35As can therefore represent more than $120 million in recurring annual expenses, not including investments in infrastructure, simulators, or strategic spare parts.

These costs limit the room for maneuver for other items of expenditure. Air base modernization programs, the acquisition of precision munitions, and the maintenance of other aircraft in operational condition may be postponed or reduced. This phenomenon, already observed in the United States and Norway, is forcing military leaders to make decisions that will have serious consequences for overall operational readiness.

On a strategic level, the integration of the F-35A commits the armed forces to long-term technological dependence on Lockheed Martin and its subcontractors. Technical support, software updates, training cycles, and even the management of certain critical parts depend directly on the manufacturer. This situation raises issues of industrial and operational sovereignty, particularly for countries that do not have autonomy over the heavy maintenance cycle.

Finally, the promise of interoperability between allies operating the F-35A must be tempered by the realities of its use: different doctrines, divergent operational needs, and varying levels of availability. Adopting the F-35A therefore means committing to a locked-in strategic framework, where operational performance is conditioned by the ability to maintain a sustained budgetary pace over several decades.

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