Airframe
The LCA is constructed of aluminium-lithium alloys, carbon-fibre composites (CFC), and titanium-alloy steels. The Tejas employs CFC materials for up to 45% of its airframe, including in the fuselage (doors and skins), wings (skin, spars and ribs), elevons, tailfin, rudder, airbrakes and landing gear doors. Composites are used to make an aircraft both lighter and stronger at the same time compared to an all-metal design, and the LCA's percentage employment of CFCs is one of the highest among contemporary aircraft of its class.[34] Apart from making the plane much lighter, there are also fewer joints or rivets, which increases the aircraft's reliability and lowers its susceptibility to structural fatigue cracks.
The tailfin for the LCA is a monolithic honeycomb piece, an approach which reduced its manufacturing cost by 80% compared to the customary "subtractive" or "deductive" method, whereby the shaft is carved out of a block of titanium alloy by a computerized numerically controlled machine. No other manufacturer is known to have made fins out of a single piece. ...means we even innovated new concepts which never existed for other planes [35] A 'nose' for the rudder is added by 'squeeze' riveting.
The use of composites in the LCA resulted in a 40% reduction in the total number of parts compared to using a metallic frame. Furthermore, the number of fasteners has been reduced by half in the composite structure from the 10,000 that would have been required in a metallic frame design. The composite design also helped to avoid about 2,000 holes being drilled into the airframe. Overall, the aircraft's weight is lowered by 21%. While each of these factors can reduce production costs, an additional benefit — and significant cost savings — is realised in the shorter time required to assemble the aircraft — seven months for the LCA as opposed to 11 months using an all-metal airframe.[6]
The airframe of the naval variant of the Tejas will be modified with a nose droop to provide improved view during landing approach, and wing leading-edge vortex controllers (LEVCON) to increase lift during approach. The LEVCONs are control surfaces that extend from the wing-root leading edge and thus afford better low-speed handling for the LCA, which would otherwise be slightly hampered due to the increased drag that results from its delta-wing design. As an added benefit, the LEVCONs will also increase controllability at high angles of attack (AoA).
The naval Tejas will also have a strengthened spine, a longer and stronger undercarriage, and powered nose wheel steering for deck manoeuvrability.[11][36] The Tejas trainer variant will have "aerodynamic commonality" with the two-seat naval aircraft design.[37]