FIA, the governing body of Formula 1, has recently unveiled a set of technical regulations for 2026 and beyond. The field is described as one with the most stringent requirements in the sports industry – and these requirements are not only related to the use of Additive Manufacturing.
In general, the new regulations target 8 key areas:
- ‘Nimble car’ concept at the heart of 2026 Technical Regulations targets improved raceability and closer racing
- 2026 cars will be 30kg lighter than current generation F1 cars improving efficiency and handling
- Redesigned power unit builds on world’s most efficient engines with almost 300% more battery power and even split between Internal Combustion and Electric power
- Active aerodynamics to suit the energy management requirements of new power units
- Increased overtaking opportunities through the new Manual Override Mode granting more electrical power deployment for the following car
- Record number of six power unit manufacturers with Ferrari, Mercedes, Alpine, Honda, Audi and Red Bull Ford Powertrains committed to F1 from 2026
- 2026 cars to run on 100% sustainable fuel
- Improved safety through stronger structures and even tougher tests
Where does AM come into play?
As far as AM is concerned, it should be noted that materials have often limited the use of the technology. So far, FIA had already approved the use of Scalmalloy® and the use of the Aheadd® CP1 aluminum additive manufacturing powder in racing cars. The fact is, these materials have often been limited to certain parts.
With the 2026 technical regulations, part manufacturers could manufacture suspension uprights via titanium and aluminum Additive Manufacturing. As explained in the FIA’s technical guide, the upright is the structural component, in the outboard suspension, which provides the physical mounting, kinematic restraint and load path connections of the wheel axle to the suspension member outboard attachments as well as the reaction of the brake caliper loads into the suspension. There can only be one suspension upright per complete wheel.
According to the new regulations, suspension uprights may only be made from additive manufactured titanium permitted by titanium alloys; Grade 1, Grade 2, Ti6Al4V, Ti6AL4V ELI, Ti 5553, Ti 6242.
On another note, these suspension uprights can also be made by aluminum alloys; AlSi10Mg, AlSi7MG, Al Cl−30AL, P339 AM, EOS Aluminium 2139 AM, Aheadd CP1 on the one hand, and on the other hand, aluminium alloys with particulate reinforcing, A20X, 2024−RAM2, 6061−RAM2.
Commenting on this release, FIA President Mohamed Ben Sulayem said: “Following the publication of 2026 Power Unit Regulations two years ago, we have taken the opportunity to redefine the chassis regulations to match the energy requirement of the new power units. Collaborating with our partners at Formula 1 and with the assistance of the sport’s 10 teams and all our stakeholders this represents a unique revision that will ensure our premier championship is even more relevant to what is happening in the world.
The Power Unit Regulations have already resulted in a record number of PU manufacturers committing to the sport. And now, in tandem with chassis regulations that provide for lighter, more agile cars featuring innovative aerodynamic solutions, we have created a set of regulations designed to not only improve racing but also to make the championship even more attractive to PU manufacturers, OEMs and existing competitors. The key features of the 2026 F1 Regulations are advanced, sustainability technology and safety. Our aim, together with Formula 1, was to produce a car that was right for the future of the sport’s elite category. We believe we have achieved that goal.”
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