Why the Comanche Helicopter, One of the U.S. Military’s Most Expensive Cancellations, Was Scrapped

In a controversial move, the Pentagon scrapped the $40 billion RAH-66 Comanche helicopter program in 2004. This next-generation aircraft, in development since 1983 for the U.S. Army, had already consumed $8 billion in funding. The Department of Defense, unable to justify the spiraling costs, pulled the plug on what would become the most expensive canceled project in U.S. military history.

Before its cancellation, military brass strongly advocated for the Comanche, citing its enhanced stealth capabilities as crucial for reconnaissance and combat operations. The joint Boeing-Sikorsky venture was slated to begin limited production in 2007, with combat readiness expected by 2009 and full-scale manufacturing in 2010.

Impressed by the Comanche’s potential, the Army had ambitious plans to acquire over 1,200 units, with initial deliveries targeted for 2006. However, the mounting costs of the stealth helicopter program ultimately proved insurmountable.

The Comanche’s design prioritized stealth, featuring internal weapons bays instead of external mounts. It boasted retractable landing gear and a foldable machine gun barrel, enhancing its low-observable profile.

To minimize radar detection, the airframe utilized advanced composite materials. The exterior was treated with radar-absorbing coatings and infrared-suppressing paint.

Twin T800-LHT-801 turboshaft engines, developed by LHTEC, a joint venture between Rolls-Royce and Honeywell, provided power. Each powerplant generated 1,560 horsepower, offering 50% more thrust than comparable engines while significantly improving fuel efficiency.

Engineers implemented an innovative exhaust cooling system to reduce the Comanche’s infrared signature. They developed a five-bladed main rotor using composite materials to address the characteristic rotor noise that often betrays a helicopter’s position. This design eliminated the need for drive shaft bearings, dramatically reducing the aircraft’s acoustic footprint.

The tail rotor received a similar treatment, with a shrouded design that minimized noise and improved survivability. These enhancements resulted in a radar cross-section just 1/660th that of the AH-64 Apache, with noise levels comparable to a passenger car at 63-72 decibels.

Survivability was a key focus, with the fuselage capable of withstanding 23mm cannon fire. Even the vulnerable tail rotor was designed to continue after taking hits from 12.7mm rounds.

The Comanche’s cockpit featured a fully sealed, pressurized chemical and biological protection environment. Advanced fly-by-wire controls and digital displays reduced pilot workload. Experts likened the Comanche’s avionics suite to a scaled-down version of the F-22 Raptor’s systems.

The pilot’s helmet-mounted display integrated data from multiple sensors, providing unprecedented situational awareness. Night vision, GPS, IFF systems, and a 3D moving map enhanced the Comanche’s night fighting capabilities beyond those of the Apache.

For armament, the Comanche carried an XM301 cannon capable of firing 20mm rounds at 750-1,500 rounds per minute from its triple-barrel system. The internal bays could accommodate six AGM-114 Hellfire missiles or twelve AIM-92 Stinger air-to-air missiles.

When stealth was not a priority, external pylons could be fitted to carry an additional eight Hellfires or sixteen Stingers. The Comanche boasted an impressive 1,367-mile range and top speeds exceeding 186 mph. During testing, prototypes logged hundreds of flight hours, demonstrating a maximum speed of 198 mph and the ability to execute a 180-degree turn in just five seconds.

Ukraine Conflict Raises Questions About Helicopter Viability in Modern Warfare

Military planners have long been concerned about the astronomical costs associated with stealth technology. The U.S. Air Force’s B-2 bomber program, initially slated for 132 aircraft, was scaled back to just 21 due to budget constraints. Similarly, F-22 production was cut from a planned 700 to 187 units. The Comanche program’s cancellation followed this trend as the Pentagon grappled with its escalating price tag.

Fielding an all-stealth fighter fleet remains financially unfeasible even for a superpower like the United States. Stealth aircraft comprise less than 10% of U.S. Air Force fighters. Plans to acquire 1,800 F-35s, which would have increased the inventory to over 80%, have reportedly been abandoned.

Recent conflicts have cast doubt on the relevance of attack helicopters in modern warfare. The ongoing Russia-Ukraine war has seen limited effectiveness of rotary-wing assets. A widely circulated video showing a Russian Mi-28 attack helicopter being downed by a Ukrainian kamikaze drone marked a watershed moment – the first confirmed instance of a drone defeating an attack helicopter in combat.

The vulnerability of high-value assets like the $16 million Ka-52 “Alligator” to relatively inexpensive man-portable air defense systems (MANPADS) has been starkly demonstrated. Estimates suggest Russia has lost over 300 helicopters since the conflict began, leading some analysts to label Ukraine a “graveyard for helicopters.”

The U.S. military is pivoting towards unmanned and optionally manned systems in response to these developments. Japan’s Self-Defense Forces, which had planned to acquire additional Apache helicopters, have canceled those contracts to bolster unmanned attack capabilities. Even Australia is reconsidering its large-scale Apache procurement, with internal debates emerging about the wisdom of such investments.