The weight issue with the MC-21 aircraft first emerged after the program transitioned to the use of domestically produced composite materials and electronic systems. Russia’s import substitution policies prompted this change. Originally equipped with foreign-made components, the MC-21-300 had a maximum takeoff weight of approximately 72.5 tons. Nevertheless, the aircraft’s weight increased considerably, nearly by 6 tons, following the transition to Russian-made materials and systems. This change resulted in the maximum takeoff weight of the MC-21-310 version being 85 tons. The Eastern Economic Forum in September 2024 marked the first formal acknowledgement of this significant weight increase. First Deputy Prime Minister Denis Manturov confirmed at that event that the import-substituted version of the aircraft had indeed become heavier, which had a negative impact on its overall operational characteristics and flight range.
Official and Media Responses
The Russian media chronicled the consequences of the MC-21’s weight increase in great detail. According to reports, the aircraft’s flight range was nearly reduced by half when flying with a complete passenger load, resulting in a range of only 2,000 to 2,800 kilometers. This range reduction effectively shifted the MC-21 from its original medium-haul aircraft category. Journalists also observed that the weight gain was not entirely related to the replacement of imported composite materials; the installation of domestic avionics and other Russian-made components also contributed to the overall increase. Denis Manturov publicly acknowledged that the government and manufacturers had been forced to consider the development of a modified version of the MC-21 with a shortened fuselage, the MC-21-210, that could accommodate 140 to 150 passengers and preserve an acceptable flight range in response to these concerns. Representatives from both PJSC “Yakovlev” and the United Aircraft Corporation (UAC) indicated that ongoing efforts were underway to reduce the weight of the aircraft. These efforts included the introduction of new composite materials and design modifications to the wing and tail structures, with the goal of reducing the aircraft’s weight by several hundred kilograms.
Current Situation and Weight Reduction Plans
At present, the Central Aerohydrodynamic Institute (TsAGI) is carrying out comprehensive testing on all prototype MC-21-310 aircraft. To implement the knowledge acquired and minimize the overall weight, engineers are consistently modifying the design of the wing, tail, and numerous fairings. One specific measure that has already demonstrated positive results is the use of new composite materials and technical solutions. This approach has enabled a reduction of 200 kilograms in the weight of the wing through a single technical improvement. In general, aircraft manufacturers are optimistic that they will be able to reduce the total weight of the aircraft by several hundred kilograms, which will partially offset the weight gain that was previously caused by the transition to domestic components. The industry’s dedication to the adoption of sophisticated materials and technologies is evidenced by the fact that composites now constitute 35 to 40 percent of the aircraft’s structural weight. This figure is a record for Russian-made airliners.
Weight Specifications as of the Present
The MC-21-300, which was the first variant with foreign components, had a maximum takeoff weight of 72,560 kilograms and a two-class range of 6,400 kilometers. Conversely, the MC-21-310, which employs components manufactured in Russia, has a maximum takeoff weight of 85,000 kilograms and a range of 5,100 kilometers. This implies that the new variant is 5.75 to 6 tons heavier than the original. The expected weight reduction of 200 to 500 kilograms is anticipated to be achieved through the implementation of new composites and other technical solutions, despite ongoing efforts to reduce weight. While the anticipated decrease represents a significant improvement, it doesn’t fully rectify the weight increase resulting from the import substitution program.
In conclusion,
The MC-21’s weight issue was first officially recognized in 2024, when it was evident that the aircraft’s weight had increased by nearly 6 tons as a result of the transition to Russian-made materials and systems. Currently, efforts are underway to reduce the aircraft’s weight through the implementation of novel composite materials and design modifications. Nevertheless, the MC-21 continues to be heavier than the original version, which was constructed with foreign components, despite the implementation of these measures. In the future, the objective is to further reduce the weight by several hundred kilograms. This could potentially restore the aircraft’s classification as a genuine medium-haul airliner and enhance its flight performance.
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