The Su-57’s production challenges include slow production rates, limited industrial capacity, and difficulties in acquiring high-tech components such as advanced avionics and microelectronics due to international sanctions.
The Soviet mentality, exemplified by the “quality over quantity” philosophy, influences decisions in Russia. Russia does not prioritise perfecting the design and systems before committing to production; instead, Russia moves ahead with what is working right now and can be mass-produced and exported to Asia and Africa without ensuring each aircraft meets fifth-generation standards.
Questionable stealth and sub-standard manufacturing
Close-up pictures are being widely shared in the Western world to suggest that the fighter program suffers from highly dubious manufacturing quality.
Pictures did indeed show the use of visible bolts, poor panel fitting, inconsistencies in assembly, and the use of bolts with varying head types. With visible gaps between many of the aircraft’s surfaces and prominent screws and rivets, the displayed fighter was indeed decades behind prevailing developments in stealth technologies. It failed to provide a genuinely fifth-generation low-observable capability.
Lacks industrial capability
Advanced technology creates manufacturing challenges. The Su-57’s sophisticated systems require precision manufacturing and specialised materials, which cannot be imported due to international sanctions.
Russia has also faced internal issues, including technical setbacks, engine delays, a skilled workforce shortage, and questions regarding the overall manufacturing quality and stealth capabilities compared to its rivals.
The production rate has been consistently slow. For example, only five aircraft were delivered by September 2025, despite an original target of 22 for that year.
The Komsomolsk-on-Amur plant, responsible for production, faces bottlenecks in its industrial capacity.
International sanctions have significantly hindered Russia’s access to critical components, especially advanced avionics, radar systems, and microelectronics.
While Russia has attempted to use dual-use civilian goods to circumvent sanctions, this can lead to issues with reliability and has resulted in visible manufacturing flaws, such as poor panel fitting, screws and inconsistent assembly, say Military Watch Magazine.
Technical and performance challenges
The program initially faced delays in developing and integrating the new AL-51F1 engine, according to The War Zone. The transition from prototype engines to production-standard powerplants has proven more complex than initially anticipated, affecting delivery timelines.
Despite some design features, experts question whether its stealth capabilities are on par with those of aircraft like the F-35, citing visible engine exhausts and the absence of radar-absorbent materials applied to the frontal and rear airframe of the plane.
The limited deployment of the aircraft in actual combat situations has raised doubts about its battlefield effectiveness.
Programmatic and financial challenges
The high cost of fifth-generation fighters competes with other military modernisation programs, and the slow production rate results in a high cost per unit.
Russian defence industries have always depended on export markets to fund their key fighter jets program. The lack of strong export demand and potential sanctions from the US on buyers have made it difficult to achieve economies of scale needed to sustain the program.
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