February 12, 2025
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February 12, 2025
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FIA’s new 2026 regulations opens the door for Metal Additive Manufacturing in Formula one

Key Takeaways
FIA's new 2026 regulations opens the door for Metal Additive Manufacturing in Formula one
FIA 2026 F1 Car regulations/Source: FIA

The Fédération Internationale de l’Automobile (FIA) has announced a new set of technical regulations for Formula One beginning in 2026, representing a significant shift in the sport’s technical and environmental standards. The FIA’s 2026 F1 regulations are expected to pave the way for metal additive manufacturing in Formula one for use in suspension uprights.

These regulations are expected to impose some of the most stringent requirements ever imposed in the sports industry, along with significant advances in a variety of areas, including Additive Manufacturing (AM).

Key FIA’s 2026 F1 regulations

The Fédération Internationale de l’Automobile was founded on June 20, 1904, to represent the interests of motoring organizations and motor vehicle owners. It is the governing body for numerous auto racing events, including Formula One. The FIA also promotes road safety throughout the world.

  • ‘Nimble Car’ concept: The ‘Nimble Car’ concept is central to the 2026 regulations, with the goal of improving raceability and ensuring close racing. The new design will focus on improving handling and efficiency by reducing car weight by 30 kg over the current generation.
  • Advanced power units: The power units will be thoroughly overhauled, with a significant increase in battery power—nearly 300 percent more than current units. They will also achieve an equal split of internal combustion engine (ICE) and electric power, further improving performance.
  • Active aerodynamics: To comply with the new energy management regulations, cars in 2026 will feature active aerodynamics systems that adapt dynamically to their power requirements.
  • Enhanced overtaking opportunities: A new Manual Override Mode will allow drivers to use more electrical power to facilitate overtaking, thereby increasing race excitement.
  • Expanded power unit manufacturers: Ferrari, Mercedes, Alpine, Honda, Audi, and Red Bull Ford Powertrains have all committed to F1’s evolving technological landscape for the 2026 season.
  • Sustainable fuel: All cars will run on 100% sustainable fuel, demonstrating the sport’s commitment to environmental responsibility.
  • Improved safety: New regulations will require stronger vehicle structures and more stringent safety tests, further protecting drivers.

“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 represents a unique revision that will ensure our premier championship is even more relevant to what is happening in the world.”

– Mohamed Ben Sulayem, FIA President

Metal Additive Manufacturing in Formula One

Formula One wind tunnel testing of 2021 car
Above: 2021 car wind tunnel testing used 50% scaled models/Image Credit: Formula 1

Under the new regulations, Additive Manufacturing will play an important role. Historically, the use of Additive Manufacturing in Formula One has been restricted by material constraints. However, the 2026 regulations create new opportunities, particularly for producing suspension uprights.

Manufacturers can now use metal additive manufacturing in suspension uprights made from titanium and aluminium alloys. The regulations specifically permit the use of titanium alloys such as Grade 1, Grade 2, Ti6Al4V, Ti6AL4V ELI, Ti 5553, and Ti 6242. Aluminium alloys such as AlSi10Mg, AlSi7MG, Al Cl−30AL, P339 AM, EOS Aluminium 2139 AM, and Aheadd CP1 are approved. The regulations also allow for aluminium alloys with particulate reinforcement, such as A20X, 2024−RAM2, and 6061−RAM2.

This move represents a significant step forward in the integration of AM technology into F1 car core components, with the potential to revolutionize how parts are manufactured and tested in the sport.

“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.”

FIA President

“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.”

F1 and 3D Printing Partnerships

Renault F1 team will be using Jabil’s AM solutions
Renault F1 team will be using Jabil’s AM solutions to speed the development and delivery of 3D printed racecar parts for the Renault R.S.19/Source: Renault Sport

Formula One teams have a long history of using 3D printed parts, whether for testing, prototypes, or actual vehicles. 3D printing companies have formed long-term partnerships with multiple Formula One teams to develop solutions, reduce costs, shorten lead times, and achieve other critical goals.

  1. Sauber partnered with 3D Systems in 2018 and purchased ProX SLA 3D printers for use in its Swiss engineering facility.
  2. In 2019, Jabil signed an agreement with the Renault F1 Team to accelerate the development and delivery of 3D printed racecar parts.
  3. In 2019, the Formula One and FIA used additive manufacturing to build 50% scaled models to test the 2021 Car Regulations.
  4. In 2021, Williams Racing collaborated with Nexa3D to 3D print functional wind tunnel components.
  5. Sauber will enter into another three-year partnership with 3D printing giant EOS in 2022 to drive their innovation efforts. The partnership centered on the continuous optimization and production of aerodynamic spoiler designs, race car end-use parts, and production aids.
  6. And just this year, in 2024, the Visa Cash App RB Formula One team is collaborating with Roboze to produce end-use parts for its single-seaters, with the goal of reducing weight and creating parts with geometries that are impossible to achieve using other techniques.

Abhimanyu Chavan
Abhimanyu is the founder of Manufactur3D and has spent more than 7 years in the 3D printing industry. He has written over 2000 articles on the technology and industry and he continues to write and share content to promote the technology across the globe, and more so in India. You can follow him on social platforms.
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