The Aeronautical Development Agency (ADA) is advancing India’s fighter jet production with a cutting-edge optical projection system aimed at replacing traditional jigs and paper blueprints. Planned for deployment on Tejas aircraft at HAL’s facilities, this AI-driven system overlays assembly instructions directly onto components using high-resolution digital projections, enhancing precision and reducing assembly errors. By enabling real-time adjustments through integration with CAD models, the system promises to cut build times significantly, boosting HAL’s Tejas production capacity from 16 to potentially over 24 jets annually. This shift supports India’s Atmanirbhar Bharat initiative by modernizing aerospace manufacturing workflows, minimizing human error, and crafting digital twins of airframes for virtual rehearsals before physical assembly. The system also aligns with India’s urgent need to increase fighter squadron numbers amid regional security challenges. Industry bids for the project are open until November 20, 2025, with trials on Tejas prototypes planned, marking a milestone in indigenous defense technology innovation and production scalability.