Members of the H-53 Heavy Lift Helicopters Program Office, known as PMA-261, have collaborated with experts at Naval Air Station Patuxent River, Maryland, and Sikorsky to identify a replacement for the search light on the CH-53K King Stallion helicopter. The initiative addresses supply challenges with the current light, ensuring continued operational readiness for the Marine Corps’ heavy-lift aircraft. Testing of the Patuxent River CH-53K search light replacement occurred in March, yielding positive results on performance and compatibility.
The Patuxent River CH-53K search light effort stems from a nearly two-year delay in obtaining the incumbent lights from the manufacturer. Like other Department of Defense aircraft, the CH-53K requires two search lights for nighttime operations, search and rescue missions, and tactical maneuvers needing enhanced visibility. The team sought a more available alternative that maintains or exceeds required standards.
Testing at NAS Patuxent River involved the Air Vehicle department from PMA-261, the Human Systems Engineering Department’s Aircraft Lighting and Transparency Lab, and Air Test and Evaluation Squadron 21, or HX-21. Pilots and subject matter experts evaluated a mixed configuration of the new and existing lights. Their feedback guides the program office in implementing the change for fleet aircraft.
“This light performs as good or better than the incumbent in visible mode, infrared radiance, illumination area and offers improved visible and dimming control,” said Daniel Harris, PMA-261 CH-53K Air Vehicle team member.
Harris noted that initial reports confirm a mixed setup is acceptable, allowing gradual integration through attrition as lights need replacement. This approach minimizes disruption to ongoing missions.
The Patuxent River CH-53K search light replacement also delivers cost savings, achieved through joint efforts between the government and Sikorsky, a Lockheed Martin company. “The new light is almost half the cost of the one it is replacing,” said Harris, “with a lead time just a fraction of that of the incumbent.”
PMA-261 continues to prioritize affordable, accessible parts to support mission readiness. The office oversees the full lifecycle of the H-53 helicopter family, including procurement, development, fielding and disposal.
The CH-53K King Stallion, designed to replace the CH-53E Super Stallion, provides advanced heavy-lift capabilities for the Marine Corps. It can transport up to 27,000 pounds externally or accommodate 55 troops internally, operating in challenging environments with improved speed and range. Development began in the early 2000s, with initial operational capability declared in April 2022 and full-rate production approved in December 2022. The aircraft features three 7,500-horsepower engines, composite rotor blades and a digital fly-by-wire system for enhanced control.
NAS Patuxent River, located in St. Mary’s County, serves as the Navy’s primary site for aviation research, development, test and evaluation. HX-21, based there, specializes in rotary-wing and tilt-rotor aircraft testing, conducting developmental flights for platforms like the CH-53K. The squadron’s work includes envelope expansion, system integration and performance assessments in various conditions.
Recent Patuxent River CH-53K search light activities build on prior milestones at the base. In January 2023, a CH-53K lifted an F-35C Lightning II airframe during external load certification, demonstrating its capacity for joint operations. Four engineering development models completed flight testing at the station in support of system demonstration, accumulating thousands of hours to validate design and safety.
The Patuxent River CH-53K search light upgrade aligns with broader affordability goals in the program. PMA-261 has pursued cost reductions through engineering changes and supply chain improvements, contributing to the helicopter’s lifecycle sustainability. The Marine Corps plans to acquire 200 CH-53Ks, with deliveries ongoing to units like Marine Heavy Helicopter Squadron 461 at New River, North Carolina.
Sikorsky, headquartered in Stratford, Connecticut, manufactures the CH-53K under a contract awarded in 2006. The company has delivered over 20 aircraft as of early 2025, with production ramping up to meet demand. International interest includes Israel’s procurement of the type to replace aging CH-53 Yas’ur helicopters, with deliveries expected in the coming years.
In March 2024, Fleet Readiness Center East at Marine Corps Air Station Cherry Point implemented new engine wash procedures for H-53 aircraft, enhancing maintenance efficiency and readiness. Such innovations complement the Patuxent River CH-53K search light work by addressing sustainment challenges across the fleet.
The Human Systems Engineering Department at Patuxent River plays a key role in ensuring aircraft components meet operator needs. The Aircraft Lighting and Transparency Lab evaluates illumination systems for visibility, compatibility with night vision devices and overall effectiveness in operational scenarios.
As PMA-261 advances the Patuxent River CH-53K search light replacement, the effort exemplifies collaborative problem-solving in naval aviation. By securing a reliable, cost-effective solution, the team supports the Marine Corps’ expeditionary capabilities, enabling transport of armored vehicles, equipment and personnel in distributed operations.
Naval Air Systems Command, or NAVAIR, oversees PMA-261 from its headquarters at Patuxent River. The command manages over 150 programs, employing thousands in Southern Maryland and contributing to the local economy through jobs and contracts. Recent developments include repurposing a retired CH-53K engineering model for maintainer training, further emphasizing sustainment priorities.
The Patuxent River CH-53K search light initiative reflects ongoing adaptations to supply chain issues, ensuring the helicopter remains a vital asset for heavy-lift missions worldwide.
