USAF considering 'very large' autonomous airborne tankers to replace KC-135, KC-46 and Boeing's MQ-25 Stingray UAV is only the beginning

Date:
Fri, 25 Sep 2026 22:35:00 +0000

Description:
US Air Force is weighing an unmanned refueling tanker, inspired by the Navy's MQ-25, but size remains a major challenge.

FULL STORY ======================================================================Copy link Facebook X Whatsapp Reddit Pinterest Flipboard Threads Email Share this article 0 Join the conversation Follow us Add us as a preferred source on Google Newsletter Subscribe to our newsletter Air Force explores unmanned tankers to replace its ageing refuelling fleet The MQ-25's progress has revived plans for autonomous Air Force tankers Range remains the biggest obstacle to building an unmanned tanker today The US Air Force is considering whether its next refueling aircraft, expected to replace the KC-135 and
KC-46, could fly with no crew aboard.

The idea gained ground because the Navy's Boeing MQ-25 Stingray, an unmanned refuelling drone , flew for the first time earlier in 2026. On Thursday, the Navy cleared the MQ-25 for low-rate production and purchased three additional units, raising its order to 14 aircraft. Latest Videos From TechRadar Watch full video here: Crews are not needed, but size remains unsolved At the
recent Air, Space & Cyber 2026 conference in National Harbor, Maryland, the Air Force said its future refueling aircraft might not need a crew.

I do not believe that it has to be manned, a future air-refuelling
solutionBut then, how do we, the U.S. Air Force, bring that to bear in scope, scale, and range? said Lt. Gen. Daniel Tulley, commander of Air Mobility Command You may like US Navy plans for 'Air Wing of the Future' with next-generation, pilotless carrier-based 1,150-mile-range drones to fly alongside manned aircraft USAF wants to replace $30 million MQ-9 Reaper
drones with cheaper UAVs after "dozens" were lost in Iran, costing taxpayers billions Boeing is turning the MQ-25 Stingray drone into an electronic
warfare heavyweight

The service is still buying Boeing KC-46 Pegasus tankers, and it spent $12 million this year to study a new tanker design.

However, its proposed fiscal 2027 budget drops that funding entirely and asks for $13 million instead, labelled as money for advanced refuelling systems. Are you a pro? Subscribe to our newsletter Sign up to the TechRadar Pro newsletter to get all the top news, opinion, features and guidance your business needs to succeed! Contact me with news and offers from other Future brands Receive email from us on behalf of our trusted partners or sponsors By submitting your information you agree to the Terms & Conditions and Privacy Policy and are aged 16 or over.

Tulley said a tanker able to cover the needed distances would be huge, and no fully autonomous aircraft of that size flies today.

The current KC-46 has a range just short of 7,400 miles and carries over
about a hundred tons of fuel.

However, the autonomous MQ-25, which is driving this idea, manages roughly
500 miles and holds up to 7.5 tons, which is a small share of what the KC-46 offers. What to read next The US Air Force wants its next generation of
target drones to mimic stealth jets The US Navy finally has a carrier with a built-in center for drones and other unmanned aircraft Pentagon is looking
for drone bombers, but don't expect a B52 replacement

Boeings aircraft can currently take off, follow programmed routes, and land
on autopilot, though the Air Force does not use them autonomously.

The Air Force is probably hoping to build on this autopilot capability,
aiming to turn the partial automation into full autonomy. Merlin Labs says autonomy can begin with crews aboard Merlin Labs, a company that builds autonomous flight systems, plans to install its autonomous pilot software on the C-130J, an aircraft similar in size to the KC-135.

The aircraft will still carry a human crew, which lets Merlin add autonomy step by step instead of jumping straight to an unmanned tanker.

That's a way that you can start to chip away at that without actually going fully to the unmanned tanker right away, said Matthew George, CEO of Merlin Labs.

The goal is that the unmanned tanker is ready, and the autonomy ends up being ready at the same time.

The company must next win certification, and it is working with the Air Force this year to get that approval.

None of this matters unless it's certified and safe. So for us, getting certification done is important, and that's what we're working really closely with the Air Force on this year, George said.

Merlin has not announced a date for the C-130J to carry its autonomous pilot, though the company's technology has completed a critical design review.

With no set flight date and unfinished certification, the Air Force's plan
for an unmanned tanker the size of the KC-46 remains far off.

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Link to news story: https://www.techradar.com/pro/usaf-considering-very-large-autonomous-airborne- tankers-to-replace-kc-135-kc-46-and-boeings-mq-25-stingray-uav-is-only-the-beg inning


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