Sikorsky is aiming to start offering a new modular and readily swappable nose for the venerable H-60 family of helicopters within the next year or so. The noses will be made available on new-production H-60s, as well as be retrofittable to helicopters in service now. The ‘nose jobs’ will help operators relatively quickly reconfigure their H-60s for very different missions, from cargo-carrying to serving as gunships, as required. It also opens new avenues to integrating autonomous capabilities and other advanced functionality.

Our Howard Altman had a chance to speak with representatives from Sikorsky, now a subsidiary of Lockheed Martin, about the plans for the new nose for the H-60-series at the Association of the U.S. Army’s (AUSA) main annual convention today. This is part of a larger vision for keeping the design operationally relevant into the 2070s, which also includes uprated engines and increased total payload capacity. You can read more about the overall Black Hawk 2070 strategy here.

Of the different elements of Black Hawk 2070, “the nose is a good one, and it’s one that’s on a pretty accelerated timeline. Within the next, I would say, year or so, the nose will be available to be retrofitted or to be coming off the line,” Jason Wrigley, Sikorsky’s director of business development for Black Hawk, said. “We’ve gone through a design cycle with it.”

As it stands now, the new nose structure will offer roughly double the physical space of the standard nose on current-generation H-60s today.

“We’ve done the design. We then 3D-printed the noses, and we did that so that we can physically interact with it, because the whole point of this is for maintainability and access to be able to integrate these different sensors and comms gear,” he continued. “We’ve gotten some feedback from the engineers, from operators, from maintainers, and that goes back into the next cycle of the design.”

Exploring ways to optimize accessibility to areas of the new nose was a major focus of this ‘test print,’ according to Wrigley. Sikorsky has a scale model on the show floor at AUSA this week that highlights how the current design opens from the top, as seen below. Ensuring that it will be possible to keep any systems inside sufficiently cooled has also been an important design consideration already.

Overall, “we just are kind of confirming, can we reach everywhere we need to? What are the different configurations?” he added. There’s been “a lot of work with the [U.S.] Army around what do you envision potentially could go in here?”

“This is one of those cases also where our whole engineering team gets more comfortable. It’s not something where the Army came to us and said, ‘this is exactly what I want. Here’s my spec,'” he also noted. “It was more, ‘here’s what I want to achieve. Here’s what I want to be able to do.’ And so we went off and designed that.”

“I like to highlight this, because it’s part of the way we’re also changing the way we design and deliver the Black Hawk,” Wrigley added as an aside. “So we’re very much in a model-based environment.”

While Wrigley mentioned sensors and communications equipment as possible payloads to fit into that extra space initially when talking with us today, he made clear later on that these are just some of the potential options.

“It’s using the old term, but it’s open architecture, and so the whole point is whatever the mission requires” can go into these new extended noses, he explained. “There’s always a demand for real estate up front.”

It’s very true that more specialized variants of the H-60, such as the MH-60s operated by the U.S. Army’s elite 160th Special Operations Aviation Regiment, often have modified noses loaded with radars, other sensors, and additional systems. The new HH-60W Jolly Green II rescue helicopters for the U.S. Air Force are another prime example of this, and there are many more.

“There’s a big focus on open architecture and that ability to quickly plug-and-play,” Wrigley also told TWZ earlier this month in the context of the larger Black Hawk 2070 plan. “The new modular nose will change the look of the Black Hawk up front to provide even more space for equipment that will work directly with the new digital architecture.”

In terms of swapping out modular noses on individual helicopters, Wrigley said that it is still too early in the design process to know exactly how that would be done and how long it might take to do so in practice.

“Part of the design process is to also write up the documentation for the retrofit, but we don’t see this one as very invasive,” he explained.

It is not hard to imagine use cases for long-nosed H-60s, especially ones that can then be reconfigured between missions, and not just for the U.S. Army. As Wrigley already underscored, there is long-standing demand for H-60s with longer and larger noses to accommodate additional mission systems. Modular noses, in general, have been becoming more and more common in aviation design for some time now.

The ability to readily swap modular noses could also allow operators of even relatively small H-60 fleets to gain a valuable new degree of multi-mission capability. As one example, cargo-carrying helicopters could be converted into gunships, and back again, as required, using a small common pool of noses with the requisite sensors, laser designators, and other equipment. All of this could offer cost benefits when it comes to sustainment and logistics, as well as added operational flexibility.

The long-nosed Black Hawk model on display at AUSA is notably configured as a gunship. Sikorsky has also talked previously about leveraging the new nose to reconfigure H-60s for search and rescue, airborne drone control, and other missions.

Just being able to install a radar for one series of missions, and then quickly switch over to an electro-optical wide-area surveillance system or another kind of sensor for the next run of sorties, would bring new adaptability to the already very flexible Black Hawk. Defensive systems could also be readily swapped from aircraft to aircraft, as well as more quickly upgraded, as needed.

The modular nose also opens the door to a new way to integrate advanced capabilities, including autonomy packages, which Wrigley said is also driving demand for more space at the front end of the helicopter. Sikorsky has been developing various tiers of autonomous capabilities for the H-60 family for years now, including artificial intelligence-driven ‘copilots’ designed just to help reduce the workload of human crew members and increase safety margins. Autonomous flight capabilities require additional sensors, such as LIDAR and cameras, to help with navigation and to provide additional situational awareness. At least some of those components could be hosted within new modular noses.

At the same time, integrating higher degrees of autonomy could require more substantial modification. Sikorsky is now developing a fully uncrewed version of the H-60, and has been doing so with an eye toward converting older Black Hawks to this configuration as they are retired from service, as you can read more about here.

In line with the Black Hawk 2070 vision, the modular noses could be part of a broader equation for modernizing existing H-60 fleets, as well.

“In our conversations with the Army, I think they’ve been using a phrase that they call targeted modernization,” Wrigley told us, speaking more generally. “There’s a daunting task that says there’s 1,000-1,500 Black Hawks in inventory. If you literally tried to upgrade every one of them, it’s a very expensive proposition, and it probably takes a long time.”

“I don’t think that’s the way they’re thinking about it. I think they’re thinking about it more on a battalion basis or a unit basis,” he continued. “Like, what’s the mission, and maybe certain Black Hawks get upgraded with autonomy, and other Black Hawks get upgraded with sort of the expanded launched effects capability, the engine, the structural upgrades, the [stub] wings, stuff like that.”

“Maybe some of them become ‘Superhawks’ or whatever, [and] get the whole package,” he added.

There is certainly still work to be done on the development of the new modular nose and then actually integrating it onto the H-60 platform. At the same time, Sikorsky clearly already sees demand for this new feature, which could lead to a breadth of new opportunities for new and old helicopters in the H-60 line.

Contact the author: joe@twz.com

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The UH-60 Black Hawk has been the rugged workhorse of U.S. Army aviation for nearly 50 years, with around 4,000 examples currently in service with 36 nations worldwide. Many of these helicopters, and new aircraft coming off the line, are set to fly as far out as 2070, and Sikorsky is curating a suite of upgrades to keep them valuable assets for the future fight. A new “digital backbone” is designed to underpin swift technological insertions such as launched effects, with related initiatives including the provision of more power to lug greater payloads, and the fully-autonomous U-Hawk cargo drone variant.

“As part of an overall “Black Hawk 2070” modernization effort we’re developing a number of complementary capabilities, including our U-Hawk uncrewed cargo variant, which we plan to fly later this year,” Jason Wrigley, Sikorsky’s director of business development for Black Hawk, told TWZ at the company’s Stratford plant in Connecticut.

“A new digital backbone for the Black Hawk is at an advanced design phase in our labs and it’s designed to provide interfaces throughout the aircraft that will provide power, data, a network, cooling and most importantly, open architecture interfaces that enable the easy integration of new equipment, such as sensors. We see this as a core building block for the next generation of Black Hawk, along with new engines and other airframe improvements designed to futureproof the platform.”

The new digital backbone is designed to work in concert with a modern, software-driven strategy that meets the Army’s Modular Open Systems Approach and the desire to add technologies cheaper, faster, and more easily. Wrigley says that as customers identify new capabilities and needs for their Black Hawks, the digital backbone will be sufficiently efficient to permit customization even on a mission-by-mission basis. Sikorsky is also introducing a new modular nose to the H-60, which is reconfigurable with sufficient volume to support even more sensors and electronics.

“There’s a big focus on open architecture and that ability to quickly plug-and-play,” says Wrigley. “The new modular nose will change the look of the Black Hawk up front to provide even more space for equipment that will work directly with the new digital architecture.”

The new modular nose will give the Black Hawk more than twice the internal volume of the original nose section and it’s designed to provide space for internal electronics and an integrated mount for external sensor pods. It is designed to provide sufficient space to accommodate electronics that enable roles such as search and rescue, drone control, and flying in degraded environments, and it will also house some of the equipment required as the Black Hawk’s autonomous capabilities expand.

Joshua Powers spent 22 years as an Army Aviation officer flying the Black Hawk, and he’s well qualified for his new role with Sikorsky handling business development for rapid capabilities insertions. “Army units know the Black Hawk inside out; how to fly it, maintain it, and use it to maximum effect. The upgrades we are developing will bring new capabilities faster, without time-consuming and complex changes to sustainment, training, and operations, plus we are adding more range, more payload, and more power to meet the demands of the Indo-Pacific region.”

“I find it amazing to pair new technology with a rugged platform like the Black Hawk. These new innovations are needed to meet the needs of the new complex battlefield. The fight I fought in Iraq is very different from the current operating environment and what future warriors are going to go up against, and what we’re asking them to do is very different from what came before.”

Bringing autonomous co-pilots to the Black Hawk

Autonomy is a central pillar of Sikorsky’s strategy for the future Black Hawk. The company’s MATRIX autonomy software is now being matured on a UH-60M variant, and while it’s not necessarily designed to completely replace pilots, MATRIX will assume some of their workload, making flying safer and simpler as mission sets grow increasingly complex and dangerous. “Pilots that are controlling collaborative drones, for example, need to be able to focus on the drone mission, and autonomy will help lighten their cognitive load,” explains Wrigley.

“The standard Black Hawk crew operates with two pilots. Adding our MATRIX autonomy system gives the operator options – a single pilot could fly without an unbearable workload and still fulfil a mission commander role, for example. The Army could then operate the Black Hawk with no pilots at all when that’s the appropriate option.”

Sikorsky’s MATRIX autonomy has been developed on the company’s UH-60A fly-by-wire Optionally Piloted Black Hawk, which has been tested by Sikorsky and Army aviators. MATRIX has accumulated more than 1,000 flight hours across 500 tests and demonstrations. It has already been integrated on over 20 different platforms, including on the Black Hawk for testing by the Defense Advanced Research Projects Agency (DARPA) and the U.S. Army in multiple exercises.

“We delivered the first UH-60MX to the Army earlier this year,” says Wrigley. The delivery marked the first full authority fly-by-wire and optionally-piloted UH-60 in the Army fleet. “They are using it for testing and soldier feedback to develop tactics, techniques and procedures for the autonomous Black Hawk. We have since received a contract to deliver three more MX aircraft to the Army.” 

MATRIX autonomy kits have now been installed on all three U.S. Army Black Hawk models; the UH-60A, UH-60L and UH-60M. Sikorsky plans to incorporate autonomy options into all Black Hawks as they are built, plus the MATRIX system will be able to be retrofitted to existing examples.

Powers is well aware of the benefits autonomy will provide from complex combat operations to more mundane day-to-day missions. “Flying at night and seeing the tracer fire coming up at you, things like that, I honestly feel that’s not the big threat. It’s when you’re going to land and there’s just a big dust cloud. When you’re tired, you aren’t as focused. Having MATRIX, whether that’s with one, two, or no pilots, it’s about that reduced workload on the mission. Pilots won’t be as fatigued, plus they have the safety net of a fully autonomous aircraft that can, if needed, land in all of those difficult environments. It will give commanders more operational flexibility and the ability to mitigate risk in less-than-ideal conditions dictated by the enemy or weather.”

“The Black Hawk operation isn’t just about pilots, it’s also that integrated four-person crew. As a pilot, you’re relying on your senses and also on the guys in the back to watch out and tell you where you’re going. MATRIX is just going to help that team effort and put you in a better position to bring the crew back safely. It integrates all the systems and sensors and uses altitude, airspeed, radar altimeter, drift indications, and puts the fly-by-wire technology to where it can make rapid adjustments and changes based on what it’s seeing with the sensors.”

The volume of testing, the maturity, and the confidence in MATRIX helped Sikorsky to develop the S-70UAS, or U-Hawk, which was unveiled in 2025. The U-Hawk project essentially removes the cockpit and its associated equipment from a Black Hawk and replaces the front end with cargo doors to provide a huge internal space as a supply drone.

“We acquired a used UH-60L Black Hawk as the template for our initial U-Hawk. We added the clamshell doors and that was the actual aircraft that we showed at AUSA last year,” says Wrigley. “Since then we’ve been adding the fly-by-wire and integrating the MATRIX autonomy. It’s currently in our innovations hangar in Bridgeport, Connecticut, getting the final work done and it will make its first flight as a U-Hawk later this year.”

Sikorsky sees the U-Hawk as a natural evolution for the Black Hawk in contested logistics missions, when cargo needs to be moved but the threat is sufficiently high that it drives a need for uncrewed platforms to tackle the mission. 

“We’re spending a lot of time on the U-Hawk and its roles. As well as being an uncrewed cargo helicopter, it can also be a truck that can carry a large volume of launched effects,” explains Wrigley. “There are Black Hawk models on the market right now that are being divested, and we see those as being an ideal option for conversion to U-Hawk configuration to affordably introduce this capability to the market.”

Drone dispenser

The integration of small drones dubbed ‘launched effects’ into rotary-wing operations is a major initiative from the Army as a new means to collect intelligence for commanders on the battlefield, relay communications, jam and distract enemy emitters, and act as loitering munitions. These mini air-launched drones can be carried and fired from stub-wing-mounted launchers, with other concepts seeing larger volumes of them carried inside the cabin as a “mega-pack,” with Sikorsky seeing both as being highly-applicable to both the Black Hawk and the U-Hawk.

This is exactly the kind of capability that the digital backbone in the Black Hawk is intended to open the door to; installing plug-and-play drone command kits, which could enable the Black Hawk to act as a “drone mothership” to launch, task, and command swarms of multi-mission launched effects.

The Army tested its latest operational concepts for launched effects during the Project Convergence Capstone 6 demonstration event this summer. This annual exercise is designed to develop concepts and tactics as well as gather soldier feedback, as it works to transition new systems into service. The latest exercise built on previous launched effects testing on the Black Hawk, when a UH-60M deployed Anduril’s Altius-700 launched effects that then operated as an autonomous hunter-killer team to locate targets, share data on those targets, and then strike them, without the need for the Black Hawk to expose itself to threats.

“As a young Black Hawk pilot, the OH-58 Kiowa Warrior was the primary scout platform, but it was limited by range and its ability to be detected,” explains Joshua Powers. “Today, we launch small drones that can remain unseen and they can give us real-time feedback. Launched effects make our lift assets more capable.”

“We see the Black Hawk as the aircraft capable of carrying, deploying and then acting as an airborne mission command node for launched effects,” adds Jason Wrigley. “In the operational environment of the future, it’s really about the mass of those launched effects. This isn’t about carrying one or two of them, this is about carrying and controlling a large number of them.”

“We’ve tested them on the stub-wings, but we are also exploring what we call “quiver” – that large number of launched effects inside the cabin in that “mega-pack.” This creates additional opportunities for mass that we think is going to be really critical. We’ve done a lot of operational analysis in concert with the Army on what the right mix of launched effects might be to extend the standoff range of the aircraft to improve survivability – which is of course what it’s all about – but the right mix will ultimately come down to the mission. We have seen a lot of testing over the past few years, so we do believe this is a capability that can be introduced operationally soon on the Black Hawk.”

More power for more missions

To support the increased lift that might be needed for a missionized Black Hawk lugging large payloads, including an arsenal of launched effects, Sikorsky is well along in development of a new engine that is designed to create over 1,000 pounds of increased payload capacity and increased range for the Black Hawk. The T901 Improved Turbine Engine (ITE) from GE Aerospace provides 50 percent more horsepower over the existing T700 engines in the UH-60M.

“One of the key building blocks of the future of the Black Hawk are the twin ITEs as we look to expand the mission capability and the utility of this aircraft for decades to come,” explains Wrigley. Sikorsky began initial testing of the first UH-60M with ITE in January 2025. “We are actively in the test program right now at our test facility in West Palm Beach, Florida. The twin ITEs in each Black Hawk and that additional power translates into some pretty significant operational opportunities. Since our first flight with ITE in May 2025 we’ve flown the aircraft with the new engine for over 50 hours and up to 17,000 ft above sea level.”

Sikorsky is accompanying the addition of the new engines with a significant expansion of the fuel tank to increase capacity and range. This is being done without impinging on cabin volume and thus retaining the important ability to transport 11 combat troops, while increasing range by around 100 nautical miles. “The T901 also improves fuel efficiency and eases maintenance – so overall we are really improving the payload capacity of the aircraft. We’ll be getting to the milestone C production decision on ITE within the next couple of years, and at that point it will become a core element of the Black Hawk program going forward,” Wrigley explains.

Building Black Hawks

Touring the Black Hawk production line in Stratford, Connecticut, it’s a hive of activity. Many of the major components for each helicopter are manufactured here. The long final assembly line sees teams of workers busily constructing UH-60M and HH-60M medevac Black Hawks for both domestic and foreign military sales customers, along with new HH-60W Combat Rescue Helicopters for the U.S. Air Force and MH-60R Seahawks.

“We’re designing all of these upgrades with the intent that they will all be available off the production line in new build aircraft, as well as in kit form for upgrades to existing assets in the field,” notes Wrigley. “Here in Stratford in what we call the “back shop” we build all the rotor blades, gearboxes, and many other components that go into each aircraft. We are already thinking ahead and we’ve invested significantly into additive manufacturing, with 11 parts on the Black Hawk today that are additively manufactured. It’s a great place to start, but there’s a long way to go and we’re working on qualifying more challenging components and load-bearing parts.”

Cohesively, the digital backbone, larger fuel tank, new engines, and the new modular nose will all be introduced on the production floor in the coming years to pave the way for that increased payload capacity to carry fully-equipped combat troops, supplies, and all the new kit needed for the future fight and the Black Hawk’s role as a multi-mission forward battlefield node. The autonomous U-Hawk and the optionally piloted flexibility afforded by MATRIX – all of these pieces of the future Black Hawk are presently coming together under an overarching effort.

“The future Black Hawk will be that complement to the future long-range MV-75 Cheyenne II,” says Powers. “These won’t be a one-for-one replacement for every Black Hawk currently in the fleet – the MV-75 has a specific purpose and function that the Black Hawk isn’t designed to do. What the Black Hawk can do with these new upgrades is shape the battlefield and with its autonomy be out there flying missions into contested environments.”

“Those homeland missions are equally necessary. I recall talking about this in flight school when choosing an aircraft to fly, how it’s one thing to be deployed on combat missions, but it’s also about being back in the homeland on disaster relief when you need the Black Hawk to go out and save lives, those kinds of missions the Army National Guard does – it really underlines the importance and versatility of the Black Hawk.”

Over the past 50 years and looking ahead to the next 50, continuing the proven legacy of the Black Hawk will mean constant evolution to meet new missions and needs. Sikorsky’s task is for all of these new elements to meld into a future Black Hawk that’s ready to roll off this production line soon, that still also provides the same dependable, rugged capability for the Army at home or overseas, well into the future.

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