FIA's 2026 F1 regulations open the door for titanium and aluminium additive manufacturing in suspension uprights

The Fédération Internationale de l'Automobile (FIA) has announced a new set of technical regulations for Formula 1 starting in 2026, marking a significant evolution in the sport's technical and environmental standards. These regulations are set to introduce some of the most stringent requirements ever imposed in the sports industry, with notable advancements in various areas, including Additive Manufacturing (AM).

The Fédération Internationale de l'Automobile is an association established on June 20, 1904 to represent the interests of motoring organisations and motor car users. It is the governing body for many auto racing events, including Formula One. The FIA also promotes road safety around the world.

Key aspects of the new regulations include:

• 'Nimble Car' concept: At the heart of the 2026 regulations is the 'Nimble Car' concept, aimed at enhancing raceability and ensuring closer racing. The new design will focus on improving handling and efficiency by reducing the weight of cars by 30 kg compared to the current generation.
• Advanced power units: The power units will undergo a major overhaul, featuring a significant increase in battery power—nearly 300 per cent more than current units. They will also achieve an even split between Internal Combustion Engine (ICE) and Electric power, further refining performance.
• Active aerodynamics: The 2026 cars will have active aerodynamics systems that adapt dynamically to their power requirements to meet the new energy management regulations.
• Enhanced overtaking opportunities: A new Manual Override Mode will allow drivers to deploy more electrical power to facilitate overtaking, increasing race excitement.
• Expanded power unit manufacturers: The 2026 season will see a record six power unit manufacturers: Ferrari, Mercedes, Alpine, Honda, Audi, and Red Bull Ford Powertrains, all committing to F1's evolving technological landscape.
• Sustainable fuel: All cars will run on 100 per cent sustainable fuel, underscoring the sport's commitment to environmental responsibility.
• Improved safety: New regulations will introduce stronger car structures and more rigorous safety tests, further protecting drivers.

The FIA President, Mohamed Ben Sulayem, commented on the release: “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."

Additive Manufacturing advances

Under the new regulations, Additive Manufacturing (AM) will play a crucial role. Historically, the use of AM in F1 has been limited by material constraints. However, the 2026 regulations open up new possibilities, particularly for producing suspension uprights.

Manufacturers can now use AM to produce suspension uprights from titanium and aluminium alloys. Specifically, the regulations permit using titanium alloys such as Grade 1, Grade 2, Ti6Al4V, Ti6AL4V ELI, Ti 5553, and Ti 6242. In addition, aluminium alloys, including 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 marks a significant step forward in integrating AM technology into the core components of F1 cars, potentially revolutionising how parts are manufactured and tested in the sport.

The FIA President added, "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."