F1 Tech | New 2026 engines: the secrets behind power unit development

Let’s uncover some lesser-known aspects behind the development of modern Formula 1 power units: from design and simulation to engine dyno testing and race optimization.

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With the 2026 regulatory overhaul approaching, F1 engines development has once again taken center stage. While the process may appear linear from the outside, it is in fact a highly complex and iterative cycle combining advanced numerical modeling, bench testing, and correlation activities.

Concept design and simulation of F1 engines

After the conceptual design stage – where the overall architecture, internal combustion engine layout, turbocharging systems, cooling strategies, and integration with the electrical components are defined – the work moves into an intensive simulation phase.

CFD (Computational Fluid Dynamics) simulations and advanced 3D thermodynamic and chemical models are used to analyze flow behavior in the intake and exhaust systems, in-cylinder flow, and combustion processes. In parallel, FEM (Finite Element Method) analyses assess mechanical loads, thermal expansion, and fatigue phenomena.

The primary objective is to minimize uncertainties before moving to physical testing, which nevertheless remains indispensable.

F1 engines dyno testing

Once the design is defined, the first units are transferred to engine test benches. In Formula 1, these systems reach extreme levels of complexity: they are capable of reproducing real operating conditions with high fidelity, precisely controlling resisting torque, load profiles, temperatures, and pressures.

It is not uncommon for teams to rely on specialized external companies, both for component manufacturing and for full product testing. This is not due to a lack of expertise, but rather to the extremely high technological specialization required. F1 test benches capable of handling engines that constantly operate at the limits of performance, mass, and reliability require dedicated infrastructure and advanced instrumentation. Therefore, its cost would be disproportionate when compared to the strict budget cap imposed by the regulations.

It is important to clarify, however, that even when using external facilities, in such an extreme environment like F1, full control of the engines testing process remains entirely with the team. Manufacturer engineers define the test programs, load profiles, operating parameters, and objectives for each run. The test bench executes the prescribed program and delivers the data, which are then internally correlated with numerical models. External companies therefore provide the testing platform, not the technical direction of development.

Single-cylinder testing

To quickly compare different configurations, especially in early development stages, it is common practice to use single-cylinder prototypes. This approach reduces time and costs, accelerates prototype manufacturing, and allows combustion, heat transfer, and flow phenomena to be isolated and analyzed more clearly than in a full engine configuration.

However, the results are not simply “scaled up.” Instead, they are integrated into models that account for cylinder-to-cylinder interactions, crankshaft dynamics, and pulsating effects in the intake and exhaust manifolds. This methodology enables validation of fundamental concepts before transitioning to full multi-cylinder units, significantly reducing the risk of unexpected issues in later stages.

The two objectives: performance and reliability

Engine dyno testing can be broadly divided into two main categories. Performance tests are used to build the characteristic curves of the power unit, measuring power and torque as a function of engine speed, turbocharging system efficiency, specific fuel consumption, and response to different control maps. These tests are conducted at steady-state operating points or through programmed sweeps and are essential for calibrating electronic management and verifying that the engine operates within the optimal region of the performance envelope defined by the regulations.

Alongside these, reliability tests simulate real operating conditions through cycles derived from championship circuits, effectively reproducing scenarios equivalent to a race weekend. Load profiles are used to replicate the most demanding tracks, combining long full-throttle periods, rapid transients, and repeated thermal cycles, with the goal of identifying early signs of degradation or potential failure mechanisms.

Reference circuits for testing

Certain circuits are used as benchmarks to assess the limits of a power unit. Monza has historically been the most severe in terms of engine usage, with over 75% of the lap spent at full throttle and long sections where the power unit operates close to maximum speed for several consecutive seconds. This makes the track a natural test case for combustion stability, thermal control, and mechanical durability.

The Mexico City circuit represents a unique challenge due to environmental conditions. In fact it is located at approximately 2,285 meters above sea level, where air density is significantly reduced. This places a heavy burden on both cooling and intake systems, imposing particularly demanding conditions from both a performance and reliability standpoint. As a result, simulations and tests replicating this circuit are among the most critical.

From engines validation to F1 race optimization

Once the baseline power unit configuration has been defined and homologated, development does not stop. In parallel with durability testing, attention shifts to fine optimization, with the objective of maximizing real-world performance over the course of race weekends. This includes refining control maps, managing operating temperatures, adapting to different circuit layouts, and seeking the best compromise between performance and component lifetime.

In an increasingly restrictive regulatory environment, the ability to accurately correlate simulations, dyno data, and on-track measurements is what separates a competitive project from a marginal one. It is within this continuous integration process that much of the competitiveness of F1 engines is determined – both today and ahead of the 2026 technical revolution.

Read also: F1 | Exclusive: What engineers see on pit wall monitors

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