Langkawi: 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.
According to BERNAMA News Agency, the issue has now been effectively addressed thanks to the innovation of a local youth who developed a system known as the Air Intake Screen Modification (AIS-Mod). 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 national heroes.
In an exclusive interview at the Langkawi International Maritime and Aerospace Exhibition 2025 (LIMA'25), Major Mohd Khairil Ashraf Maton, head of Avionics Flight at the RMAF's Aerospace Engineering Services Centre (PUSPEKA), reported that from 2016 to last year, a total of 38 incidents involving engine damage due to foreign object ingestion were recorded. Of those, 19 cases were caused by birds, leading to losses of nearly RM700 million. In response, his team from the 12th Squadron 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.
The project is founded on a low cost, high impact concept, focusing 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. Field tests conducted earlier successfully demonstrated the system's effectiveness, with two potentially serious incidents averted thanks to AIS-Mod.
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 disclosed that two previous cases of Sukhoi engine damage caused by bird strikes and foreign object ingestion had resulted in losses totaling RM46 million.
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, with no further incidents of engine damage caused by foreign objects.
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 developed for the EC725 helicopters operated by 5th and 10th Squadrons. Previously, these helicopters were equipped with a forward-looking infrared (FLIR) camera but lacked a recording system. According to 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, allowing the aircraft to 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.
RAIN's innovation has received 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 required repairs in Spain, taking nearly two years. The RWR B-Sensing system enables domestic repairs, thereby improving operational readiness and cost management.
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.