S-400 Triumf LR-SAM System Model – Design & Development

Basic Information

Project Title	Design & Development of S-400 Triumf Long-Range Surface-to-Air Missile (LR-SAM) System Scale Model (Sudarshan Chakra)
Duration	07th December 2025 – 23rd January 2026
Venue	Workshop 514 (Carpentry Workshop), Thakur College of Engineering & Technology, Kandivali (East), Mumbai
Unit	TCET NCC Army Wing
Mentor & OIC	Cdr. Vijay Pratap Singh (Retd.)
ANO	Lt. (Dr.) Nivant Kambale
Project Leader	JUO Ashish Tiwari
Cadet Participants	17

Event Context

As part of structured NCC training activities and in preparation for the Republic Day Celebration 2026, the TCET NCC Unit undertook this defence-oriented technical initiative. The project was conceived to translate theoretical understanding of modern integrated air defence systems into structured, hands-on engineering application for NCC Army Wing cadets.

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Introduction

As part of structured National Cadets Corps (NCC) training activities and in preparation for the Republic Day Celebration 2026, the TCET NCC Unit undertook a defence-oriented technical initiative involving the design and development of a dimensionally standardized scale engineering model of the S-400 Triumf Long-Range Surface-to-Air Missile (LR-SAM) System. The initiative was conceived to translate theoretical understanding of modern integrated air defence systems into structured, hands-on engineering application for NCC Army Wing cadets.

The S-400 Triumf represents a network-centric air defence architecture comprising surveillance radars, engagement radars, command-and-control units, and transporter-erector-launcher (TEL) platforms functioning in coordinated deployment. The modelling activity was designed to provide cadets with conceptual clarity regarding subsystem interdependence, deployment logic, and structural configuration within such an integrated defence framework. The project emphasized experiential learning through blueprint development, proportional scaling, structural fabrication, mechanical integration, and disciplined system assembly.

The initiative was executed under the guidance of Cdr (Retd.) Vijay Pratap Singh, Mentor & Officer-In-Charge, and Lt. (Dr.) Nivant Kambale, Associate NCC Officer, ensuring adherence to NCC training standards, institutional safety norms, and structured supervision protocols. Beyond technical skill development, the project strengthened leadership, accountability, teamwork, and defence awareness, aligning engineering education with national security consciousness and the core values of the National Cadets Corps.

Technical Components Developed

The complete model comprised six interlinked sub-models representing key operational components of the S-400 Triumf system:

5P85TE2 Launcher Vehicle (TEL)

Representing the missile launching platform with four launcher tubes arranged in a 2×2 configuration. The Transporter-Erector-Launcher (TEL) is the primary firing unit of the S-400 system, capable of carrying and launching various missile types including the 48N6 long-range missiles. The scale model accurately depicts the chassis configuration, launcher tube arrangement, and support stabilizers.

92N6E "Grave Stone" Engagement Radar

Depicting the fire-control radar responsible for target engagement and tracking. The 92N6E Grave Stone is a multifunctional phased-array radar that provides precise target illumination for missile guidance. The model represents the radar antenna array, rotating mechanism, and associated control equipment mounted on a mobile platform.

91N6E "Big Bird" Long-Range Surveillance Radar

Representing the primary detection and battle management radar system. The 91N6E Big Bird is a long-range acquisition radar capable of detecting aerial targets at extended ranges. The scale model showcases the large antenna array structure, support mast, and mobile deployment configuration essential for early warning and target designation.

96L6E All-Altitude Detection Radar

Simulating multi-layer detection capability across varying altitudes. The 96L6E is a 3D surveillance radar providing all-altitude target detection and tracking capabilities. The model illustrates the distinctive antenna configuration, elevation scanning mechanism, and mobile deployment features that enable comprehensive airspace monitoring.

55K6E Mobile Command Post

Representing the command-and-control node coordinating radar and launcher operations. The 55K6E serves as the central command post for the S-400 battery, housing operator stations, communication equipment, and battle management systems. The model depicts the mobile shelter configuration, antenna masts, and operational workspace layout.

40V6MR Telescopic Mast System

Demonstrating elevation support for enhanced radar coverage. The 40V6MR is a mobile telescopic mast designed to elevate radar antennas for improved line-of-sight and extended detection range. The scale model accurately represents the extendable mast sections, hydraulic elevation mechanism, and stabilizer deployment configuration.

Skills Practiced (Career-Relevant)

This project enabled cadets to gain hands-on exposure to engineering principles and career-relevant skills:

Technical Skills

Blueprint interpretation
Proportional scaling
Structural fabrication
Mechanical integration
Precision fabrication

Engineering Skills

Surface finishing
Camouflage application
Structural stability principles
Load distribution
Axis-based rotation concepts

Management Skills

Mechanical alignment
Subsystem integration
Project management
Team coordination
Time-bound execution

Baseline Scaling Approach

The wheel (tyre) dimension was selected as the primary reference parameter for scaling. This component was chosen because:

Consistent visibility: It is consistently visible across multiple reference images.
Reliable proportional anchor: It provides a reliable proportional anchor for vehicle chassis length and height.
Dimensional uniformity: It maintains dimensional uniformity across launcher, radar, and command vehicles.

Using the tyre diameter as a base measurement, cadets applied ratio calculations to derive:

Chassis length and width
Cabin dimensions
Launcher frame proportions
Radar mast heights
Launcher tube diameters and spacing
Telescopic mast sectional reductions

Image-based proportional measurement tools were used to determine relative dimensions from scaled photographs. These proportional values were then converted into real fabrication measurements using scale factor calculations.

Digital Tools Utilized

To facilitate blueprint development and dimensional verification, cadets utilized:

Sketchfab: for 3D visualization and structural orientation reference
Canva: for structured layout drafting and schematic alignment
Image measurement tools: for proportional dimension extraction from scaled visual references

These tools enabled accurate interpretation of visual data and systematic conversion into structured fabrication-ready schematics. This structured blueprint and scaling methodology transformed the modelling activity from approximate crafting into a disciplined engineering-based fabrication exercise aligned with technical documentation standards.

Materials and Tools Utilised for Modelling & Crafting

Sr.No	Title / Item	Remarks / Project Application
1	MDF Board	Used for fabrication of main vehicle chassis, launcher platforms, and radar base structures. Utilised for auxiliary vehicle panels, support frames, and internal reinforcements.
2	Artificial Modeled Tyres	Used as wheels for Transporter-Erector-Launcher (TEL) vehicles and command vehicles.
3	Radio Antennas	Used for external antenna detailing on radar and command vehicles.
4	PVC Pipe, Vetra, Hacksaw File	Used for crafting missile launcher tubes, cutting components, and structural bonding. Used for cutting MDF, crafting nets, window grills, and fine structural detailing.
5	Air Gasket, Hydraulic	Used to simulate hydraulic movement and stabilizing mechanisms.
6	Bearing, Jar Screws	Enabled rotational movement of radar units and articulated components.
7	Cutter, Hacksaw, Sandpaper	Primary tools for cutting, shaping, and surface finishing.
8	Bamboo Stick	Used for fine structural detailing and internal supports.
9	Bamboo Stick (Large)	Used for masts, radar arms, and stabilizer extensions.
10	Hinges, Sandpaper	Used for making movable doors, panels, and surface finishing.
11	Antenna – 6	Used for radar and communication unit detailing.
12	Laminated Sheets	Used for smooth surface panels and aesthetic detailing.
13	Tar, Syringe	Used for minor bonding, wire detailing, and surface finishing. Used for adhesive application and simulated hydraulic detailing.
14	Welding	Used for strengthening metal joints and supports. Additional welding support for structural reinforcement.
15	Pipe Jointer	Used for joining launcher tubes and support frames.
16	Syringe	Used to simulate hydraulic pistons and stabilizer mechanisms.
17	Vetra, Tar, Sandpaper	Used for bonding, smoothing, and finishing surfaces.
18	Bamboo Stick (Small)	Used for miniature detailing and internal bracing.
19	Bolt, Bearing, Hook	Used in movable joints, antenna rotation, and stabilizers.
20	Pipe Caps, Hinges, Bolt	Used for launcher ends, doors, and movable parts.
21	Nut, Hooks, Sandpaper	Used for fastening, detailing, and surface finishing.
22	Bamboo Stick	Used for additional detailing and reinforcement.
23	Ball Bearings, Nut Bolt	Used for smooth rotation of radar assemblies.
24	Surgical Mask – 40	Used as personal protective equipment for cadets during sanding and cutting.
25	Paints – Green, Red	Used for base coat and identification markings.
26	Vicer	Used as small workshop utility tool.
27	Nails	Used for securing MDF and wooden structures.
28	Zip Tie	Used for cable management and temporary fixtures.
29	Paints – Green	Used for camouflage base coat.
30	Bamboo Stick	Used for support arms and detailing.
31	Brushes	Used for paint application and detailing.
32	Paints – Green, Dark Green, Muddy Yellow, Thinner	Used for final camouflage painting and finishing.
33	Paint Brushes	Used for detailed painting and touch-ups.
34	Wire Tape	Used for securing wiring and detailing.
35	Lighter – 2	Used for heat-shrinking and finishing wire elements.
36	Miscellaneous	Used for minor unforeseen requirements during fabrication.
37	Tennis Ball	Used for shaping launcher base and structural support.

ADS S400 Design & Modelling Team Members

Sr. No.	Rank & Name	Assigned Responsibility
1	Cdr Vijay Pratap Singh	Conceptualized, Initiated and Guided
2	Lt. Dr. Nivant Kambale	Guidance
3	JUO Ashish Tiwari	Project Leader; Strategic Coordination and Overall Project Completion
4	JUO Prerit Kumar	Fabrication of Missile Launch Tubes and Base Primer Application
5	Cdt Sachin K. Prasad	Blueprint and Schematic Analysis; Supervision of Scaling and Critical Fabrication
6	LCpl Gautam Patil	Engineering and Shaping of Heavy-Duty Chassis Bases and Vehicle Cabins
7	Cpl Manav Negi	Fine Sanding, Surface Detailing and Painting
8	LCpl Kirish Mahto	Material Logistics, Assembly Assistance, Base Primer and Painting
9	Cdt Ankesh Yadav	Fabrication of Articulated Masts, Stairs, Doors, Hinges and Painting
10	SUO Snehaal Vishwakarma	Precision Crafting of 91N6E Big Bird Radar Unit, Part Detailing and Painting
11	LCpl Omkar Joshi	Timber Sizing, Precision Part Cutting and Initial Shaping
12	LCpl Raunak Prajapati	Structural Woodwork, Carving of Heavy Vehicle Cabins and Painting
13	Cpl Abhishek Vishwakarma	Material Innovation, Camouflage Design Layout and Decal Application
14	Cdt Rahul Kumawat	Timber Sizing, Precision Cutting and Initial Model Shaping
15	Cpl Disha Mate	Fine Sanding, Surface Detailing and Painting
16	Cpl Manasvi Sawant	Fine Sanding, Surface Detailing and Painting
17	Cdt Smit Kudchikar	Wood Turning and Carving of Hydraulic Stabilizers and Support Legs