AIS-Mod: RMAF Innovation Shields Fighter Jets From Bird Strike Threats

By Maizatul Jamny Muhammad Rosli

LANGKAWI, May 24 (Bernama) -- What appears to be a minor natural hazard - small birds soaring freely in the skies - has emerged as a costly threat to Malaysia’s defence sector, with damages reaching into the hundreds of millions of ringgit.

Beneath the calm of the airspace lies a hidden danger faced by pilots - particularly those of the Royal Malaysian Air Force (RMAF). Birds being sucked into aircraft engines during takeoff and landing can cause severe damage, disrupt operations, and compromise flight safety.

However, thanks to the innovation of a local youth who developed a system known as the Air Intake Screen Modification (AIS-Mod), the issue has now been effectively addressed. This system now serves as a silent guardian for the nation's fighter jets, saving millions of ringgit and, more importantly, safeguarding the lives of our national heroes.

In an exclusive interview with Bernama at the Langkawi International Maritime and Aerospace Exhibition 2025 (LIMA’25), head of Avionics Flight at the RMAF's Aerospace Engineering Services Centre (PUSPEKA), Major Mohd Khairil Ashraf Maton, said that from 2016 to last year, a total of 38 incidents involving engine damage due to foreign object ingestion were recorded.

“Of that number, 19 cases were caused by birds, leading to losses of nearly RM700 million. In response to this alarming trend, my team from 12th Squadron and I began research into the development of AIS-Mod in 2021, specifically for the Sukhoi Su-30MKM fighter aircraft, to enhance its air intake protection system,” he said.

“This project is founded on the low cost, high impact concept. We focused on enhancing the efficiency of the existing air filter screen and adjusting the screen’s opening time during takeoff and landing, the two most critical phases, where the risk of bird strikes is highest,” he explained.

He added that field tests conducted earlier successfully demonstrated the system’s effectiveness. In fact, two potentially serious incidents were averted thanks to AIS-Mod, a significant achievement that highlights the real-world value of local innovation.

Mohd Khairil Ashraf further explained that engine damage not only entails high repair costs, often requiring the engine to be sent back to the manufacturer but also impacts the RMAF’s operational readiness due to the lengthy repair timeline.

He also disclosed that two previous cases of Sukhoi engine damage caused by bird strikes and foreign object ingestion had resulted in losses totaling RM46 million, a substantial figure for just two engines.

Initially, four AIS-Mod prototypes were developed, beginning with Beta 1. However, the early version failed to meet safety standards, while Beta 2 and Beta 3 were too large to be fully installed. After continuous research and refinement, the fourth prototype finally succeeded in meeting all technical and safety requirements.

“Currently, all Sukhoi aircraft participating in LIMA’25 are equipped with AIS-Mod. Ahamdulillah, there have been no further incidents of engine damage caused by foreign objects,” he said, adding that even in areas such as the Air Force College (KTU) in Kepala Batas, Kedah, known for its high bird population, the system has proven effective.

The AIS-Mod, which earned second place in the 2025 RMAF Innovation Award, is now in the process of expanding production, with four additional units underway. This will bring the total to 10 units, further strengthening the protection of the nation’s fighter aircraft against small threats that pose significant risks.

The AIS-Mod is one of seven innovations showcased at the RMAF Pavilion in conjunction with LIMA’25. However, two other major projects have also drawn significant attention: the Revolution Advanced Innovation Network (RAIN) and the Radar Warning Receiver Blind Sensing (RWR B-Sensing) systems.

The RAIN project was specifically developed for the EC725 helicopters operated by 5the Squadron and 10th Squadron. Previously, these helicopters were only equipped with a forward-looking infrared (FLIR) camera, but lacked a recording system.

According to Staff Officer 2 (Innovation), Major Muhammad Syafiq Syahmi Muhammad Suhaimi, the RAIN system enables real-time video recordings to be transmitted directly to the operations centre during flight missions. This capability significantly enhances RMAF operational effectiveness and improves team safety.

“RAIN enables real-time recording, and as the aircraft is flying, it can simultaneously transmit a live feed to the operations centre on the ground. This allows the pilot to concentrate fully on flying, without being distracted by additional tasks such as documenting or reporting, thereby reducing the pilot’s workload during missions.

The system also empowers the operations centre to conduct immediate assessments, and the recorded footage can serve as critical evidence in court proceedings, particularly in cases involving violations of national airspace or maritime law.

RAIN’s innovation has also earned international recognition, securing three gold medals in South Korea, surpassing entries from 57 other countries. It also received the prestigious DNA Public Sector Innovation Award.

Another noteworthy innovation is the RWR B-Sensing system, developed for the A400M aircraft. This system was created to replace the original threat detection unit, which previously had to be sent to Spain for repairs, a process that could take nearly two years and incur significant costs.

“RWR is a system designed to detect threats or electronic signatures. It’s a highly sensitive component with a special coating, making it impossible to repair domestically. What our team has done is fabricate an in-house replica, an exact one-to-one design of the original RWR, but without the sensor, using the expertise available within the RMAF.

“So, when we fly missions that do not require the RWR function, we can remove, preserve and install RWR B-Sensing and at the same time if it does get damaged we have the capability to carry out composite repairs at the Subang and Butterworth air bases,” he said.

Most recently, the system was used in a mission to rescue the people of Gaza in Egypt when an aircraft that was supposed to be unflyable for two years was successfully activated in a short time.

-- BERNAMA