How Do Teams Develop An F1 Car?

How do teams develop an F1 car? As with most things in Formula One, planning and detail are everything. When developing a car and deciding what to update, teams first have to put together a plan of what needs to be worked on – where are the strengths they can maximise further and where are the weaknesses that they can improve?
 
When choosing an upgrade, teams must focus on the areas that are going to produce the most performance in the quickest timeframe, and also find the balance between where you go looking and the size of the project you take on.
 
As a rule of thumb, the bigger the part, the longer it is going to take to design, manufacture and bring to the track. Teams also have to consider how critical a part is to the structure of the car. A crucial structural part such as the front and rear wings, which are highly loaded, have to be put through rigorous tests to meet strict safety regulations, so those components tend to be defined and decided on pretty early.
 
Next up, when looking at aerodynamics, teams focus their attention on the floor and diffuser, which are big downforce generators and have long lead times. And then it’s about looking into the components that are smaller and quicker to make but bring a lot of performance, such as brake ducts, bargeboards and engine covers.
 
Once the areas of focus have been defined, the general process of bringing an upgrade to the track will depend on the component, but whether it’s an internal or external part, they all need to be designed and tested, before the decision is made to move forward with the concept or find another solution.
 
If we take an aero part as an example, the Aerodynamics department will come up with a range of concepts and solutions, which will then be designed and tested in Computational Fluid Dynamics (CFD) simulations. The best options will be turned into components for the Wind Tunnel model, where they’ll be trialled in the Tunnel, before the final solution is given the green light to be manufactured and brought to the track. This entire process can take several weeks, which is why planning the upgrades and creating a solid development timeline is so important.
 
Many of the innovative designs can’t be seen on TV, but instead lie under the bodywork of the car, such as the gearbox or cooling systems. Often, what we find here are lots of small things, which are easy to implement and can be introduced between the main upgrades.
 
One of the most interesting internal areas to upgrade is the engine, as all the action happens in the combustion chambers. Engineers can create and bring numerous updates to the engine, but from the outside, it’s hardly noticeable.
 
That was true for the DAS steering system that Mercedes developed for 2020, which was only visible because the drivers moved the steering wheel backwards and forwards, bringing to life an innovation that would have otherwise been invisible to the outside world.

What happens to F1 concepts that don’t make the cut?

What everyone sees being brought to the track is just the tip of the iceberg when it comes to upgrades. There can be hundreds and thousands of different solutions that are thought up in the design process, but not all of those will be put through testing – for example with aero components, going through CFD.
 
Once the virtual testing has taken place, only a handful of concepts will be brought to the Wind Tunnel to get a more realistic and accurate feel for how they will react to the airflow around the car. And from those designs, just one will be brought to the track as part of the upgrade package.
 
Every part has a hundred brothers and sisters that went with it, to try and find the best solution, with numerous people involved and hours and hours of work going into making every little detail count. Most of those brothers and sisters will never see the light of day, but that’s not to say they are completely wasted. Indeed, they create important learnings and bring inspiration for the next solutions – one of which will eventually make it to the track. Whether the part is internal or external, it’s all about trial and error, that’s how you improve and find the right direction.

What’s it like for the driver when an upgrade is brought to the car?

The drivers are constantly updated on the development progress of the car, so they know when things are coming, what to look out for and what feedback the team would like from them. Getting a correlation between the Wind Tunnel and the real world is incredibly difficult, so the direct feedback engineers get from the driver is really useful for them to see how an upgrade has changed the car’s performance and balance.
 
“The first time you get on the track, it is really difficult to feel the differences in the car because you end up just going faster,” said Lewis Hamilton. “It can be disguised in the balance. The areas that you do often notice is if the rear is more stable, so if you get more rear downforce, that is often the one that you perhaps notice the most.
 
“It’s not always easy to feel it, but there is a huge amount of work that goes into bringing an upgrade to track – so much detail, so much design and then the build process. When you go to the factory and you see everyone at their workstations, head down, focussed, determined, staying overtime to get projects finished, it’s amazing. And then you see the ideas that get turned into CAD drawings, and then it becomes a physical piece – it is mind-blowing to see.
 
“The creative genius of all these individuals is super inspiring. It gets you excited, we’ve got new bits coming or there might be something that we’ve wanted for some time, but it takes months to build and when you finally get it, and you put it on the car, and you can feel the difference, it’s amazing.”

How the budget cap influences F1 development

The introduction of the budget cap in 2021 has been one of the most significant changes to the financial landscape of Formula 1 in recent years. The cap, set at $145 million for the 2021 season and gradually decreasing to $135 million by 2023, has forced teams to fundamentally rethink their approach to car development.

Under the budget cap, teams must carefully allocate their resources to maximize performance gains while staying within the prescribed financial limits. This has led to a greater emphasis on efficiency and innovation in the development process. As Toto Wolff, Team Principal of Mercedes-AMG Petronas Formula One Team, explained, “The budget cap has changed the game. We have to be smarter in how we approach development, focusing on the areas that deliver the most bang for the buck.”

One of the key challenges teams face is striking the right balance between short-term upgrades and long-term development projects. With limited resources, teams must prioritize updates that offer immediate performance benefits while also investing in research and development that could yield significant advantages down the line. According to James Key, Technical Director at Sauber, “The budget cap has forced us to be more strategic in our development plans. We have to carefully weigh the potential gains of each upgrade against the resources required to implement it.”

The budget cap has also led to increased scrutiny of every aspect of car development, from the materials used in construction to the time spent in the wind tunnel. Teams are constantly seeking ways to optimize their processes and find marginal gains that could make the difference on track. As Andrew Green, former Technical Director at Aston Martin Cognizant Formula One Team, noted, “Every decision we make now has to be viewed through the lens of the budget cap. We’re always asking ourselves, ‘Is this the most efficient use of our resources?'”

One area where teams have found opportunities for cost savings is through increased collaboration and knowledge sharing. By working more closely with suppliers and partners, teams can pool resources and expertise to drive innovation while reducing costs. This has led to a rise in strategic partnerships and technology transfer agreements across the sport.

The budget cap has also had a leveling effect on the competitive landscape of Formula 1. With financial resources more evenly distributed, smaller teams have a better chance of closing the gap to the front-runners. As Franz Tost, former Team Principal of Scuderia AlphaTauri, observed, “The budget cap has given us a fighting chance. We may not have the same resources as the bigger teams, but we can now compete on a more level playing field.”

However, the budget cap has not been without its challenges. Teams have had to adapt to new financial reporting and compliance requirements, which has added an additional layer of complexity to their operations. There have also been concerns about the potential for teams to find loopholes or creative ways to circumvent the cap, which could undermine its effectiveness.

Despite these challenges, the consensus among team principals and technical directors is that the budget cap is a necessary step for the long-term sustainability and competitiveness of Formula 1. As Ross Brawn, former Managing Director of Motorsports at Formula 1, summed up, “The budget cap is not just about controlling costs; it’s about creating a more level playing field and ensuring that Formula 1 remains the pinnacle of motorsport innovation for years to come.”

Wind Tunnel Restrictions

The introduction of wind tunnel testing restrictions in 2022 has added another layer of complexity to the car development process in Formula 1. Under the new regulations, teams are allocated wind tunnel time based on their position in the previous year’s Constructors’ Championship, with the team finishing last receiving the most time and the team finishing first receiving the least.

The goal of this handicap system is to level the playing field and prevent dominant teams from perpetually outspending and out-developing their rivals. As Mattia Binotto, COO and CTO of Sauber explained, “The wind tunnel restrictions are designed to close the gap between the top teams and the midfield. It’s about creating a more competitive and exciting championship.”

However, the restrictions have also forced teams to be more strategic in their approach to wind tunnel testing. With limited time available, teams must prioritize the development areas that will yield the most significant performance gains. This has led to a greater emphasis on data analysis and simulation tools to optimize the use of wind tunnel time.

According to Mike Elliott, former Technical Director at Mercedes-AMG Petronas Formula One Team, “The wind tunnel restrictions have changed the way we approach development. We have to be much more targeted in our testing, focusing on the areas that will deliver the greatest returns in terms of lap time.”

One of the challenges teams face is ensuring that the data collected in the wind tunnel correlates with real-world performance on the track. With fewer opportunities to validate designs in the tunnel, teams have had to invest in more advanced simulation tools and rely more heavily on computational fluid dynamics (CFD) to refine their concepts.

As Tom McCullough, Performance Director at Aston Martin Cognizant Formula One Team, noted, “The wind tunnel restrictions have pushed us to develop more sophisticated simulation tools. We’re using machine learning and AI to analyze data and predict how design changes will perform on the track.”

The restrictions have also led to a greater emphasis on collaboration between departments within the team. Aerodynamicists, chassis engineers, and simulation specialists must work closely together to maximize the efficiency of wind tunnel testing and ensure that the data collected is effectively translated into performance gains.

The impact of the wind tunnel restrictions on the competitive order of Formula 1 remains to be seen, but early indications suggest that they are having the desired effect of closing the gap between teams. As Andreas Seidl, former Team Principal of McLaren Racing, observed, “The wind tunnel restrictions have definitely made things more challenging, but they’ve also created opportunities for teams to innovate and find new ways to gain a competitive advantage.”

However, some have raised concerns about the potential unintended consequences of the restrictions. There are fears that teams may shift resources away from wind tunnel testing and towards other areas of development that are not as tightly regulated, such as CFD or track testing.

Despite these concerns, the wind tunnel restrictions have been widely embraced as a necessary step towards creating a more sustainable and competitive Formula 1. As Ross Brawn concluded, “The wind tunnel restrictions are part of a broader package of measures designed to level the playing field and create closer racing. It’s about ensuring that success is determined by innovation, creativity, and hard work, rather than just financial muscle.”

Sustainability Driving Development

The push for sustainability has become a major focus in Formula 1 in recent years, with the sport introducing a range of measures designed to reduce its environmental impact. From the development of more efficient power units to the use of sustainable materials in car construction, teams are now required to consider sustainability alongside performance when developing their cars.

One of the key initiatives has been the introduction of new technical regulations aimed at promoting the use of more sustainable fuels. Starting in 2026, F1 cars will be required to run on a 100% sustainable fuel, with a mix of bio-components and synthetic elements. This has led to a significant research and development effort among teams and fuel suppliers to create a new generation of sustainable high-performance fuels.

As Christian Horner, Team Principal of Red Bull Racing, explained, “The move to sustainable fuels is a critical step for Formula 1. It’s not just about reducing our carbon footprint; it’s about driving innovation and showing that sustainability and performance can go hand in hand.”

The focus on sustainability has also led to a reexamination of every aspect of car design and construction. Teams are now exploring the use of renewable and recyclable materials in the production of chassis, bodywork, and other components. This includes the use of natural fibers, such as flax and hemp, as well as recycled carbon fiber and bio-based resins.

According to James Allison, “Sustainability has become a key driver of innovation in Formula 1. We’re constantly looking for ways to reduce waste, minimize our environmental impact, and create a more circular economy within the sport.”

The push for sustainability has also led to closer collaboration between teams and their suppliers and partners. By working together to develop new sustainable technologies and practices, the sport as a whole is driving progress towards a more environmentally friendly future.

As Zak Brown, CEO of McLaren Racing, noted, “Sustainability is not just a buzzword in Formula 1; it’s a shared responsibility. By working together as a sport, we have the opportunity to make a real difference and set an example for other industries to follow.”

However, the transition to sustainability is not without its challenges. Developing new sustainable technologies and materials requires significant investment and resources, which can be difficult to justify in a sport where performance is paramount. There are also concerns about the potential impact on the spectacle of Formula 1, with some fans worried that the move to sustainable fuels and materials could lead to a reduction in speed and excitement.

Despite these challenges, the commitment to sustainability in Formula 1 remains strong. As Jean Todt, former President of the FIA, concluded, “Formula 1 has always been a laboratory for innovation, and the transition to sustainability is no exception. By embracing this challenge and working together as a sport, we have the opportunity to create a better, cleaner, and more responsible future for motorsport and beyond.”

The integration of sustainability into the car development process represents a significant shift in the priorities and practices of Formula 1 teams. While the pursuit of performance remains the ultimate goal, teams must now balance this with the need to minimize their environmental impact and contribute to a more sustainable future for the sport. As the transition to sustainability continues to gather pace, it is clear that it will play an increasingly important role in shaping the future of Formula 1 car development.

Portions of this article were provided by Mercedes press release.