The concept phase
Every F1 car begins as a concept — a set of performance targets defined by the technical director and chief designer. These targets include downforce levels, drag coefficients, weight distribution, cooling requirements, and packaging constraints. The concept phase can take months, and it involves hundreds of engineers working in parallel.
The first step is to define the car's "envelope" — the maximum dimensions allowed by the regulations. Within this envelope, the aerodynamics team begins shaping the bodywork, the chassis team designs the monocoque, and the power unit team determines the engine and hybrid system packaging.
CFD: the digital wind tunnel
Before any physical model is built, the car is tested in computational fluid dynamics (CFD) simulations. These simulations model airflow around the car at racing speeds, revealing areas of high and low pressure, turbulence, and drag.
CFD is incredibly powerful — it can test thousands of design variations in the time it takes a wind tunnel to test dozens. But it is not perfect. The mathematical models that simulate real-world airflow are approximations, and they can miss subtle effects that only appear when air meets a physical surface.
Wind tunnel validation
The best CFD designs are then tested as scale models in the wind tunnel. Here, real-world data validates the simulations. Engineers measure downforce, drag, and airflow patterns, comparing the results to the CFD predictions. If there is a discrepancy, the CFD model is refined and the process repeats.
The wind tunnel is limited by FIA regulations — teams are allowed a certain number of runs per week, and the amount of time is tied to their championship position. This means every wind tunnel run must be carefully planned and executed.
The 2026 design challenge
The 2026 regulation changes have made the design process more complex. The new Active Aero system requires teams to design wings that can change configuration during a race. The lighter minimum weight target means every component must be optimized for weight reduction. And the increased electrical component of the power unit requires new cooling systems and new packaging solutions.