After over 800 hours of testing, the gearbox is expected to receive Federal Aviation Administration (FAA) certification in 2025. Four units have already been completed at Sikorsky’s Stratford headquarters, and there is significant interest from customers to adopt the new technology.
“The Phase IV gearbox is the result of more than a decade of development, testing, and optimization,” said Leon Silva, Vice President of Global Commercial and Military Systems at Sikorsky. “It continues to build on the solid foundation established by previous versions of the gearbox.”
Sikorsky invested over $100 million into the Phase IV gearbox’s development. The S-92 helicopter, used primarily in offshore energy operations, is also employed for search and rescue, head of state transportation, and other critical missions globally.The Phase IV gearbox is expected to increase the S-92 fleet's operational efficiency, with a lifetime availability of over 90%. This is particularly important for S-92 aircraft, which often log more than 1,500 flight hours annually in offshore energy operations. The new gearbox is designed to support the growing demands of deepwater operations, providing a reliable means of transporting personnel and supplies to remote locations.
In addition to the gearbox, Sikorsky has recently introduced other enhancements to the S-92 platform, such as extended scheduled inspection intervals and a one-time life extension for specific main gearbox housings. These improvements are expected to reduce downtime and increase the operational lifespan of the aircraft.