USAF aims to power on new Air Force One aircraft this year ahead of first flight in 2027

The US Air Force (USAF) is preparing to switch on the electrical systems of its next-generation Air Force One aircraft later this year, marking another important step toward the aircraft’s first flight.

According to Aviation Week, the USAF expects to power on the first Boeing VC-25B later this year, with the aircraft scheduled to make its first flight in 2027. The update suggests that a program that has faced years of delays is finally making measurable progress.

The new aircraft are intended to replace the two ageing VC-25A aircraft that have served as presidential transports since the 1990s.

Powering on is an important milestone

Switching on the aircraft’s electrical systems is an important milestone in a complex aircraft program. Once the aircraft is powered, engineers can continue testing its systems and checking that the different parts of the aircraft work together as intended.

While the first flight will be an even bigger milestone, there is still considerable work to complete before that happens. The USAF says the first flight is expected next year, while delivery of the first new presidential aircraft is targeted for 2028.

Electrical work is finally underway

The VC-25B program is based on Boeing’s 747-8 aircraft. Two aircraft are being modified to become the next official Air Force One jets. Originally ordered by the US Government in 2018, the programme to convert the aircraft for presidential use has been beset with cost overruns and delays.

Aviation Week reported that the program is currently completing electrical work before the first aircraft can be powered on. Boeing has also been working to bring in more electricians to support the effort.

The aircraft have also undergone major structural work. This includes repairs to cracks found in structural stringers, which are important parts of an aircraft’s internal framework.

Gen. Dale White, the USAF official overseeing major programs, told reporters at the Air Force Association’s Air, Space & Cyber Conference that there had been “tremendous progress” on the VC-25B program. He said the USAF is concentrating on the areas that are most important to get the aircraft delivered.

A program that has faced long delays

The new Air Force One program has been troubled by delays, rising costs and technical problems. The original plan called for the aircraft to be delivered in 2024. The first VC-25B is now expected to arrive in 2028, several years later than originally planned.

Boeing has also faced problems completing the aircraft’s design and manufacturing work. In July, the company announced another financial charge related to the program as it worked to move the project forward.

White said the additional funding has helped Boeing deal with unfinished design work and other problems caused by the long delay. He also said the relationship between Boeing and the USAF had improved, with the company now focused strongly on meeting the 2028 delivery target.

Window and windshield problems

Another issue involves the certification of spare windshields and passenger windows. As previously reported by Aerospace Global News, a recent USAF acquisition report highlighted concerns over these components. The problem is not limited to the two presidential aircraft and affects a wider group of aircraft.

White said he had recently received an update on the issue and believed that it was moving in the right direction.

For a presidential aircraft, such certification work is particularly important. The VC-25B cannot simply enter service because it is based on an existing commercial aircraft. It needs extensive modifications, testing, and certification to meet USAF requirements, as well as strict US Government security guidelines.

The Qatar-gifted aircraft is helping to bridge the gap

While Boeing works on the two permanent VC-25Bs, the USAF has gained valuable experience from another 747-8. The aircraft, known as the VC-25B Bridge, was donated by the Qatari government in 2025 and modified for presidential use.

It was delivered to the Presidential Airlift Group in June 2026 after completing modification and flight testing. It was most recently seen in presidential use, flying President Trump to Dublin in Ireland over the weekend of 12/13 September.

The temporary aircraft is more than a stopgap. It is also helping USAF personnel learn how to operate and maintain the 747-8. White told reporters that the aircraft has taught the service about the unique requirements of operating, maintaining, and sustaining the 747-8.

That experience could save time when the two Boeing-built VC-25Bs arrive because the aircraft are based on the same basic platform.

A slow road toward a new Air Force One

The VC-25B program has taken far longer than originally expected, but the latest update indicates that progress is accelerating. This year’s planned power-on will test whether Boeing can keep the aircraft on track for its first flight in 2027.

For the USAF, the goal is not simply to produce another 747. The VC-25B must become a secure and highly specialised command and communications platform capable of carrying the president around the world.

If the current pace continues, the next major milestone will be the first flight. After years of delays, that flight will offer the clearest sign yet that America’s next generation of Air Force One aircraft is finally becoming a reality.