{"$schema":"nativecad-dfm-pack/1","id":"motorsport","title":"Motorsport: how F1 and top-level race cars are made","sector":"motorsport","version":"2026-11-04","summary":"How F1 and other race cars are made and homologated: survival cell laminates and FIA 2026 tests, the carbon part path, metallics and AM, brakes, cages and FSAE, with rule years. Numbers are tagged SRC or EST.","aliases":["f1","formula 1","formula one","motorsport","race car","racing car","monocoque","survival cell","crash structure","wishbone","halo","le mans","hypercar","lmp","gt3","formula sae","fsae","indycar","carbon brake","roll cage","push rod","uprights","brake disc"],"crossSector":false,"size":"full","sources":[{"id":"fia-2026-c21","title":"FIA 2026 Formula 1 Regulations, Section C Technical, Issue 21 (19 Oct 2026)","url":"https://www.fia.com/system/files/documents/fia_2026_f1_regulations_-_section_c_technical_-_iss_21_-_2026-10-19.pdf","accessed":"2026-11-04","note":"Numbers change by issue."},{"id":"fia-art253-2020","title":"FIA Appendix J Article 253-8 safety cages, 2020 edition (WMSC 09.10.2020)","url":"https://fia.com/sites/default/files/253_2020_chap_8_wmsc_2020.10.09.pdf","accessed":"2026-11-04","note":"Groups N, A, R-GT. A later edition may drop the build-to-spec route; check the car year."},{"id":"fia-art257a-2024","title":"FIA Appendix J Article 257A, Group GT3 technical regulations, 2024 edition","url":"https://www.fia.com/sites/default/files/257a_2024.pdf","accessed":"2026-11-04"},{"id":"cw-brembo-2025","title":"CompositesWorld, Plant tour: Brembo, Bergamo, Italy (G. Gardiner, 20 Oct 2025)","url":"https://www.compositesworld.com/articles/plant-tour-brembo-bergamo-italy","accessed":"2026-11-04"},{"id":"brembo-2020","title":"Brembo, all the latest news from Brembo for the F1 season (17 Jul 2020)","url":"https://www.bremboparts.com/europe/en/news/all-the-latest-news-from-brembo-for-the-f1-season-194986","accessed":"2026-11-04"},{"id":"f1-tech-tuesday-brakes","title":"Formula1.com Tech Tuesday: how teams cope with brake-killer Canada","url":"https://www.formula1.com/en/latest/article/tech-tuesday-how-teams-cope-with-brake-killer-canada.3kBWl0EqlqGoMAAIiIMAoi","accessed":"2026-11-04"},{"id":"driver61-brembo","title":"Driver61, How Brembo creates the F1 carbon-carbon brake system","url":"https://driver61.com/motorsport-engineering/how-brembo-creates-f1s-100000-carbon-carbon-brake-system/","accessed":"2026-11-04","note":"Trade explainer. Its 3 mm hole minimum disagrees with FIA 2026 C11.3."},{"id":"cw-f1-2020","title":"CompositesWorld, The untapped potential in Formula 1 composite manufacture (B. Skuse, 22 Jun 2020)","url":"https://www.gardnerweb.com/articles/the-untapped-potential-in-formula-1-composite-manufacture","accessed":"2026-11-04"},{"id":"motorsport-r24-composites","title":"Motorsport.com, R24 project: producing the composites (6 Dec 2003)","url":"https://au.motorsport.com/f1/news/r24-project-producing-the-composites/1090083/","accessed":"2026-11-04","note":"Renault R24 build diary; old, but one of the few team-published ply and shape counts."},{"id":"motorsport-r24-final","title":"Motorsport.com, R24 project: the final stages (2003)","url":"https://au.motorsport.com/f1/news/r24-project-the-final-stages/1090711/","accessed":"2026-11-04"},{"id":"f1chronicle-how-made","title":"F1 Chronicle, How is a Formula 1 car made?","url":"https://f1chronicle.com/how-is-a-formula-1-car-made","accessed":"2026-11-04","note":"Fan-trade explainer; no primary citation for its figures."},{"id":"f1i-production","title":"F1i, Tech: the birth of a Formula 1 car, the production phase","url":"https://f1i.com/magazine/magazine-technical/290512-tech-f1i-birth-formula-1-car-production.html/2","accessed":"2026-11-04"},{"id":"autosport-upgrades","title":"Autosport, How F1 teams actually produce car upgrades in five steps","url":"https://www.autosport.com/f1/news/how-f1-teams-actually-produce-car-upgrades-in-five-steps/10727725/","accessed":"2026-11-04"},{"id":"driver61-alpine-fw","title":"Driver61, How Alpine F1 engineers build front wings","url":"https://driver61.com/motorsport-engineering/how-alpine-f1-engineers-build-front-wings-7-days-of-precision-manufacturing/","accessed":"2026-11-04"},{"id":"f1-williams-vowles","title":"Formula1.com, How James Vowles is plotting the Williams return to form","url":"https://www.formula1.com/en/latest/article/playing-the-long-game-how-new-boss-james-vowles-is-plotting-williams-return.5p5BNEcnIQ6G5IDYWyonhN","accessed":"2026-11-04"},{"id":"curley-pushrods","title":"Curley, Mallon, Gilchrist, Compression strength of composite suspension push-rods for Formula 1 racing cars (UCD)","url":"https://researchrepository.ucd.ie/rest/bitstreams/12140/retrieve","accessed":"2026-11-04","note":"University specimens that could typically be used, not team parts."},{"id":"ai-sauber-am","title":"Additive Industries, Kick Sauber F1 Team case study: safety critical structural titanium parts","url":"https://fip.utwente.nl/wp-content/uploads/2024/11/IN13_TechInno_KickSauber-F1Team-and-Additive-Industries_EN.pdf","accessed":"2026-11-04","note":"Machine-vendor case study; part figures attributed to the team."},{"id":"3ds-scalmalloy","title":"3D Systems, Certified Scalmalloy (A) datasheet (2022)","url":"https://3dsystems.com/sites/default/files/2022-02/3d-systems-certified-scalmalloy(a)-datasheet-usen-2022-02-23-a-print.pdf","accessed":"2026-11-04"},{"id":"hpm-gearboxes-2011","title":"High Power Media, Formula One gearboxes (15 Dec 2011)","url":"https://www.highpowermedia.com/Archive/formula-one-gearboxes","accessed":"2026-11-04"},{"id":"hpm-composites-2012","title":"High Power Media, Composites (L. Butcher, 27 Sep 2012)","url":"https://www.highpowermedia.com/Archive/composites","accessed":"2026-11-04"},{"id":"autosport-gearbox-2014","title":"Autosport, F1 2014 tech: gearboxes under pressure","url":"https://www.autosport.com/f1/feature/5826/f1-2014-tech-gearboxes-under-pressure","accessed":"2026-11-04"},{"id":"driver61-gearbox","title":"Driver61, What makes an F1 gearbox worth so much","url":"https://driver61.com/motorsport-engineering/inside-f1-gearbox-250k/","accessed":"2026-11-04"},{"id":"the-race-rollhoop","title":"The Race, What FIA intends to change after the Zhou F1 rollhoop failure","url":"https://www.the-race.com/formula-1/what-fia-intends-to-change-after-zhous-f1-rollhoop-failure","accessed":"2026-11-04"},{"id":"f1-tech-tuesday-halo","title":"Formula1.com Tech Tuesday: a close look at the halo","url":"https://www.formula1.com/en/latest/article/tech-tuesday-a-close-look-at-the-halo-and-how-it-saved-hamiltons-neck-in.68Ajvw12Xza2P3JvuXGRO3","accessed":"2026-11-04"},{"id":"aprc-clutches","title":"AP Racing, carbon/carbon clutches range page","url":"https://apracing.com/race-car/carboncarbon-clutches","accessed":"2026-11-04"},{"id":"ec-eb700","title":"Easy Composites, EB700 high temperature epoxy tooling board datasheet rev 2 (2019)","url":"https://media.easycomposites.eu/datasheets/EC-TDS-EB700-High-Temperature-Epoxy-Tooling-Board-v2.pdf","accessed":"2026-11-04"},{"id":"wiki-safety-wire","title":"Wikipedia, Safety wire (cites FAA AC 43.13-1B and MS33540)","url":"https://en.wikipedia.org/wiki/Safety_wire","accessed":"2026-11-04"},{"id":"wiki-mpi","title":"Wikipedia, Magnetic particle inspection (names ASTM E1444)","url":"https://en.wikipedia.org/wiki/Magnetic_particle_inspection","accessed":"2026-11-04"},{"id":"wiki-dpi","title":"Wikipedia, Dye penetrant inspection (names ASTM E1417)","url":"https://en.wikipedia.org/wiki/Dye_penetrant_inspection","accessed":"2026-11-04"},{"id":"wtt-4130","title":"Welding Tips and Tricks, 4130 chromoly tubing TIG","url":"https://www.weldingtipsandtricks.com/4130-chromoly-tubing.html","accessed":"2026-11-04","note":"Shop practice source, not a standard."},{"id":"motorsportmag-hypercar","title":"Motor Sport magazine, Le Mans Hypercar: entries, rules and specs","url":"https://www.motorsportmagazine.com/articles/sports-cars/le-mans-hypercar-latest-entries-rules-and-specs-for-the-new-sports-car-category","accessed":"2026-11-04"},{"id":"fe-gen3","title":"FIA Formula E, GEN3 facts","url":"https://www.fiaformulae.com/en/news/2439/gen3-facts-performance-x-efficiency-x-sustainability","accessed":"2026-11-04"},{"id":"msw-aeroscreen","title":"Motorsport Week, Lighter aeroscreen in works for 2024 IndyCar season (24 May 2022)","url":"https://motorsportweek.com/2022/05/24/lighter-aeroscreen-in-works-for-2024-indycar-season/","accessed":"2026-11-04"},{"id":"fsae-rules-unca","title":"FSAE rules F.3.4 as published on a university chassis rules site (2024 rulebook)","url":"https://sites.google.com/unca.edu/chassis/chassis-rules/f-3-tubing-and-material/f-3-4-steel-tubing-and-material","accessed":"2026-11-04"},{"id":"dj-fsae-2026","title":"Design Judges, Guide to 2026 FSAE frame rule changes","url":"https://www.designjudges.com/articles/guide-to-2026-frame-rule-changes","accessed":"2026-11-04"}],"entries":[{"id":"part-path-overview","kind":"process","tier":1,"title":"The carbon part path: pattern, mould, plies, cure, trim, bond","summary":"5-axis mill an epoxy pattern (reported to +/-0.05 mm), lay a carbon mould on it, hand-lay prepreg with laser-guided ply placement, bag, debulk, autoclave, trim, bond, paint, inspect. Model the mould surface side as the true surface and give every part a pull direction.","applies":["carbon part","wing","bodywork","chassis"],"basis":"SRC: F1 Chronicle (+/-0.05 mm, 5-axis epoxy pattern, carbon mould, autoclave), F1i, CompositesWorld 2020 (laser ply placement). EST: debulk, trim, bond, paint, inspect steps and mould-side-as-datum advice; no team spec public.","sources":["f1chronicle-how-made","f1i-production","cw-f1-2020"],"tags":["prepreg","process"],"value":{"value":0.05,"unit":"mm","note":"pattern accuracy, one trade source"}},{"id":"autoclave-window-race","kind":"process","tier":1,"title":"Race part cure window as published: 3-7 bar, about 100-250 C","summary":"Published window for race prepreg: about 100-250 C at 3-7 bar. A Renault R24 chassis first cure ran 3-4 h at up to 180 C and about 100 psi, with 2-3 lower-temperature debulks per skin. Mould and inserts must survive this cycle.","applies":["autoclave","chassis","wing"],"basis":"SRC: printed figures, not a team spec, and vary by resin. Current team cycles are unpublished.","sources":["autosport-upgrades","motorsport-r24-final"],"tags":["cure"],"value":{"table":[{"source":"Autosport","temp_C":"100-250","pressure":"3-7 bar"},{"source":"Renault R24","temp_C":"up to 180","pressure":"about 100 psi","time_h":"3-4"}]},"see":["composites/cure-cycle-8552"]},{"id":"chassis-construction","kind":"process","tier":1,"title":"Survival cell: two moulded halves, skin, core, skin, drilled inserts","summary":"Upper and lower halves are moulded separately: outer skin (150-200 plies on the R24, autoclave-cured first), then core and inner skin. Inserts go in, halves are CNC-drilled in jigs for pick-ups, then bonded together. Model the cell as two shells with a bond flange, not one solid.","applies":["monocoque","survival cell","chassis"],"basis":"SRC: Motorsport.com 2003 (150-200 plies; outer skin cured before core and inner skin; jig drilling; halves bonded); F1 Chronicle says several hundred plies per chassis. EST: two-shell-with-flange advice. Current counts unpublished.","sources":["motorsport-r24-composites","motorsport-r24-final","f1chronicle-how-made"],"tags":["plies","bond"],"value":{"min":150,"max":200,"unit":"count","note":"outer skin plies, Renault R24, 2003"},"see":["composites/potted-insert"]},{"id":"intrusion-laminates","kind":"test","tier":1,"title":"Survival cell homologated intrusion laminates (2026)","summary":"2026 test panels must resist, through a 100x130 mm rigid pad: HL-COCKPIT-SIDE 440 kN, HL-FWD-SC, HL-COCKPIT-FLOOR and HL-FC-SIDE 325 kN. Sandwich panels need Al honeycomb of 6 mm or more and at least 800 gsm CC-UHS per skin. Zone is mainly Z 100-550 on the sides.","applies":["survival cell","anti-intrusion"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.3.1, C15.5.3. Recesses and inserts must keep equivalent intrusion strength.","sources":["fia-2026-c21"],"tags":["zylon","homologation"],"value":{"table":[{"laminate":"HL-FWD-SC","load_kN":325,"form":"sandwich"},{"laminate":"HL-COCKPIT-SIDE","load_kN":440},{"laminate":"HL-COCKPIT-FLOOR","load_kN":325},{"laminate":"HL-FC-SIDE","load_kN":325,"form":"sandwich"}]},"see":["materials/composite-cf-epoxy"]},{"id":"cell-static-tests","kind":"test","tier":1,"title":"Survival cell static load tests (2026)","summary":"2026 pads: fuel tank side 110 kN on dia 225; wheel contact 100 kN, 15 mm max; floor 25 kN; cockpit floor 75 kN; rim 50 kN on dia 50, under 10 mm; cockpit side 300 kN, 30 mm max. Permanent set limits 1-3 mm. Local skin must carry these with no failure.","applies":["survival cell","monocoque"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.4. C13.4.2-7 run on every cell, within 120% of reference deflection; cell mass within 5%.","sources":["fia-2026-c21"],"tags":["homologation","push-off"],"value":{"table":[{"art":"C13.4.2","test":"fuel tank side","pad_mm":225,"kN":110,"set_mm":3},{"art":"C13.4.3","test":"wheel contact XC -1195","pad_mm":200,"kN":100,"max_mm":15,"set_mm":3},{"art":"C13.4.4","test":"cell floor","pad_mm":200,"kN":25,"set_mm":1},{"art":"C13.4.5","test":"cockpit floor XC -600","pad_mm":200,"kN":75,"set_mm":3},{"art":"C13.4.6","test":"cockpit rim XC -250","pad_mm":50,"kN":50,"max_mm":10,"set_mm":1},{"art":"C13.4.7","test":"cockpit side","pad_mm":225,"kN":300,"max_mm":30},{"art":"C13.4.10","test":"forward cell","kN":30,"max_mm":5}]}},{"id":"impact-tests-dynamic","kind":"test","tier":1,"title":"FIA dynamic impact tests (2026): front, cell, rear","summary":"2026: FIS 900 kg at over 17 and over 14 m/s, peak 40 g, 150 mm must survive. Cell frontal 900-925 kg at 15 m/s or more with 500 kN crush tubes, displacement 425 mm max. Rear 875 kg at 11 m/s or more, 25 g max. Keep inserts and hard parts out of the crush length.","applies":["crash structure","nose","rear impact"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.2, C13.6, C13.7. FIS limit curve 13.5/X^1.13 g; rear 15+26.5X g. FIA-F1-DOC-002 is not public.","sources":["fia-2026-c21"],"tags":["crash","fis","ris"],"value":{"table":[{"art":"C13.6.5","test":"FIS test 1","kg":900,"m_s":17,"peak_g":40},{"art":"C13.6.6","test":"FIS test 2, after push-off to failure","kg":900,"m_s":14,"peak_g":40},{"art":"C13.2","test":"cell frontal","kg":"900-925","m_s":15,"note":"peak at least 52 g after T=30 ms"},{"art":"C13.7.3","test":"rear","kg":875,"m_s":11,"peak_g":25}]}},{"id":"fis-section-rule","kind":"rule","tier":1,"title":"Front impact structure sections and attachments (2026)","summary":"2026 FIS: at least 4 equal-strength attachments; sections grow monotonically; at XFIS 50 over 9000 mm2 enclosing 120x65; at XFIS 150 over 20000 mm2; XA -400 to -100 taper 45000 to 60000 mm2; behind XFIS 250 normals within 25 deg of an X-plane.","applies":["nose","crash structure"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.6.1. Cell and FIS section hulls within 7 mm at XA 0 (C12.2.2 h).","sources":["fia-2026-c21"],"tags":["section area","nose"],"value":{"table":[{"station":"XFIS 50","min_area_mm2":9000,"encloses":"120 x 65"},{"station":"XFIS 150","min_area_mm2":20000},{"station":"XA -400","min_area_mm2":45000},{"station":"XA -100","min_area_mm2":60000}]}},{"id":"roll-hoop-rule","kind":"rule","tier":1,"title":"Principal roll structure geometry and loads (2026)","summary":"2026 roll hoop: min 6000 mm2 at Z 950, min 10000 mm2 at Z 910 enclosing a 70 mm square; above Z 935 tangent continuous, no concave radius, convex R 20 or more; 60x30 mm strap opening; 172 kN test with under 25 mm deformation; no particulate-reinforced metal.","applies":["roll hoop","airbox"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.4.1, C13.3.1, C15.3.4. The 2022 rule was 60/70/105 kN (The Race): do not reuse old loads.","sources":["fia-2026-c21","the-race-rollhoop"],"tags":["strap"],"value":{"table":[{"z":950,"min_area_mm2":6000},{"z":910,"min_area_mm2":10000,"encloses":"70 mm square"},{"item":"convex radius above Z 935","min_mm":20},{"item":"test load","kN":172,"hold_s":10,"max_mm":25}]}},{"id":"halo-mount-rule","kind":"rule","tier":1,"title":"Halo is bought, not designed: mounts and loads (2026)","summary":"The 2026 halo is made to FIA8869-2018 by designated suppliers; model mounts, not the frame. Front fixing axis XC -975, Z 660; rear faces on Z 695. Attachments see 130.1 kN down + 51.6 kN rearward, and 104.5 kN inward + 93.2 kN rearward. Fairings use PL-HALO.","applies":["halo","secondary roll structure"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.4.2, C13.3.2. Earlier cases 116/46 and 93/83 kN (Formula1.com). FIA-F1-DOC-115 is not public.","sources":["fia-2026-c21","f1-tech-tuesday-halo"],"tags":["fia8869"],"value":{"table":[{"test":"centreline","down_kN":130.1,"rearward_kN":51.6,"at":"[Xc-785, 0, 830]"},{"test":"lateral","inward_kN":104.5,"rearward_kN":93.2,"at":"[Xc-590, 233.5, 810]"}]}},{"id":"suspension-member-section","kind":"rule","tier":1,"title":"Suspension members: constant symmetric section on the load line (2026)","summary":"2026 members: section normal to the load line has 2 orthogonal axes of symmetry, constant size, shape and incidence, centroid within 5 mm of the line (10 mm on the steering link). Fairings: no dimension over 100 mm, aspect 3.5:1 max. Sweep a constant profile; do not taper it.","applies":["wishbone","push rod","track rod"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.3.6, C3.17.3. Minimal exceptions: adjusters, line and tether passage, rod-end attachment, gauges. One rear member per side exempt. Inner wall taper is not addressed.","sources":["fia-2026-c21"],"tags":["wishbone","aerofoil"],"value":{"table":[{"item":"centroid to load line","max_mm":5},{"item":"steering link centroid","max_mm":10},{"item":"fairing section","max_mm":100},{"item":"fairing aspect","max_ratio":3.5}]}},{"id":"wheel-tether-rule","kind":"rule","tier":1,"title":"Wheel tethers and their attachments (2026)","summary":"2026: 3 tethers per wheel to FIA 8864-2022, 15 kJ total, each at least 3 kJ. Each end withstands 70 kN within a 90 deg cone, no bend radius under 7.5 mm, no shared fastener. Two tethers at least 300 mm apart on the cell, 250 mm on the gearbox, 100 mm and 90 deg on the upright.","applies":["tether","upright","wishbone"],"basis":"SRC: FIA 2026 Section C Iss 21 C14.4.1. Demand: wishbone section passes the tether; anchors need separate inserts.","sources":["fia-2026-c21"],"tags":["insert","zylon"],"value":{"table":[{"item":"attachment load","kN":70},{"item":"bend radius","min_mm":7.5},{"item":"spacing on cell","min_mm":300},{"item":"spacing on gearbox","min_mm":250},{"item":"spacing on upright","min_mm":100,"min_deg":90},{"item":"tethers in one member","max_count":2}]}},{"id":"brake-size-rule","kind":"rule","tier":1,"title":"Brake disc, calliper and cooling limits (2026)","summary":"2026 discs: 34 mm max thick; dia 325-345 front, 260-280 rear; cooling holes dia 2.5 or more. Callipers: aluminium, at most 3 attachments, 1 to 4 opposing piston pairs, circular pistons. No liquid cooling. Discs, pads and callipers are OSC, so bought in.","applies":["brake disc","brake calliper"],"basis":"SRC: FIA 2026 Section C Iss 21 C11.2, C11.3, C11.7. Earlier years were 278 mm and 32 mm (Formula1.com).","sources":["fia-2026-c21","f1-tech-tuesday-brakes"],"tags":["cooling hole"],"value":{"table":[{"item":"disc thickness","max_mm":34},{"item":"front disc dia","min_mm":325,"max_mm":345},{"item":"rear disc dia","min_mm":260,"max_mm":280},{"item":"cooling hole dia","min_mm":2.5},{"item":"calliper attachments","max_count":3},{"item":"piston pairs","max_count":4}]}},{"id":"wheel-rim-rule","kind":"rule","tier":2,"title":"Wheel rim: forged magnesium with a revolved profile (2026)","summary":"2026 rims: AZ70 or AZ80 magnesium, one revolved tangent-continuous profile, min R 8 in the styled zone, cut surfaces concave R 6 or more, wall 2.5 min, bead 4.0 min, not handed. Rim dia 462.5/463, tyre mounting width 315 front, 401.3 rear, lip OD 496.","applies":["wheel","rim"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.7.1, C10.7.2. Key-dimension table re-read in PDF text order: rows rim dia, mounting width, lip OD, overall width, outboard and inboard lip align with the values. Bead is the ETRTO profile.","sources":["fia-2026-c21"],"tags":["wheel","magnesium","revolve"],"value":{"table":[{"item":"wall","min_mm":2.5},{"item":"bead","min_mm":4},{"item":"profile radius","min_mm":8},{"item":"cut concave radius","min_mm":6},{"item":"rim dia","mm":"462.5/463"},{"item":"mounting width","front_mm":"315 +/-0.5","rear_mm":"401.3 +/-0.5"},{"item":"lip OD","mm":"496 +/-0.5"},{"item":"overall width","front_mm":"334 ref","rear_mm":"420.3 ref"},{"item":"lip thickness","outboard_mm":"8.5 +/-0.2","inboard_mm":"10.5 +/-0.2"}]}},{"id":"materials-limits","kind":"material","tier":1,"title":"What F1 parts may be made of (2026)","summary":"2026 metal limit: specific modulus 40 GPa/(g/cm3) max. Carbon: PAN, modulus 550 GPa max, strength 7100 MPa max, density 1.92 max. Be, Li and exotic alloys restricted. Commercially available materials only, declared each year.","applies":["material choice","homologation"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.1.4, C15.2. Closed lists: an unnamed material is not allowed. Coatings max 0.8 mm (C15.4 h).","sources":["fia-2026-c21"],"tags":["regulation","c15"],"value":{"table":[{"item":"metal specific modulus","max":"40 GPa/(g/cm3)"},{"item":"carbon tensile modulus","max_GPa":550},{"item":"carbon tensile strength","max_MPa":7100},{"item":"wrought Al Li, ex 2050/55/99","max_pct":1},{"item":"copper beryllium","max_pct":2.5}]}},{"id":"uprights-materials","kind":"material","tier":1,"title":"Uprights: the only allowed alloys (2026)","summary":"2026 uprights only: wrought 2014, 2618, 7075 or 7022 aluminium, wrought or cast permitted titanium, listed Al MMC, or additive Ti or Al. Parts inboard of YW 0 stay inside an R25 sphere round each pick-up. One upright per wheel.","applies":["upright","hub carrier"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.3.3, C10.6.","sources":["fia-2026-c21"],"tags":["aluminium","titanium"],"value":{"options":["2014","2618","7075","7022","listed Ti","SupremEX 225","AM Ti","AM Al"]},"see":["materials/al-7075-t6","materials/ti-6al-4v"]},{"id":"calc-criterion","kind":"rule","tier":1,"title":"Where calculation stands in for a test: reserve factor 1.0 (2026)","summary":"Regulation calculations use reserve factor 1.0 at ultimate for metals and first-ply failure for composites (2026). Design laminates to first-ply, not last-ply. Examples: cockpit side 380 kN, nose 110 kN, frontal bulkhead 215 kN. FIA may ask for models.","applies":["survival cell","fea"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.1.3, C12.3.2, C13.4.7, C13.4.8. Report cad_fea_case and cad_laminate results against this.","sources":["fia-2026-c21"],"tags":["first ply failure","fea"],"value":{"value":1,"unit":"ratio","note":"reserve factor at ultimate for metals, at first-ply failure for composites"},"see":["composites/first-vs-last-ply"]},{"id":"side-impact-structures","kind":"rule","tier":2,"title":"Side impact structures and their bonded mountings (2026)","summary":"2 per side, 2026 design per FIA-F1-DOC-108: upper at Z 400-550, lower at Z 75-100, laterally within 15 mm. Bonded interface at least 44 mm long; mount has a closed end and abutment taking 100/150 kN squeeze with no help from the bond. Keep hard parts 20 mm clear.","applies":["side impact","survival cell"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.5.1 to C13.5.4. A mechanical abutment behind the bond is the requirement to copy on any bonded structural spigot.","sources":["fia-2026-c21"],"tags":["side impact","bond","abutment"],"value":{"table":[{"item":"squeeze upper","kN":100},{"item":"squeeze lower","kN":150},{"item":"push-off rearward upper","kN":40},{"item":"push-off rearward lower","kN":60},{"item":"push-off up, lower","kN":35},{"item":"calc down, upper","kN":27},{"item":"bond length","min_mm":44}]},"detail":"Mount lies inboard of a plane 292 mm from the outer end of the tube. Structure is empty outboard of 342 mm (upper) or 357 mm (lower) for debris compaction, with projected Z area over 7440 and 9225 mm2. Recess area per structure is 8000 mm2 max on a Y-plane. Part locations: upper XC -500 to -375, lower XC -525 to -425. The DOC-108 drawings themselves are not public."},{"id":"rear-impact-rule","kind":"rule","tier":2,"title":"Rear impact structure geometry and static tests (2026)","summary":"2026 rear structure conforms to RV-TAIL-RIS within +/-0.5 mm from XDIF 325 to 750; perimeter at least 1.6 mm thick and uniform between 50 and 200 mm from the rear face; 3 static tests of 40 kN at XDIF 500 through gearbox joint. Foam (SG under 1) does not count.","applies":["rear impact","gearbox"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.7.1, C13.7.2. Gearbox fixed by the engine studs for test. All damage must stay behind XR 0 in the dynamic test.","sources":["fia-2026-c21"],"tags":["ris","gearbox","wall"],"value":{"table":[{"item":"perimeter wall","min_mm":1.6},{"item":"form tolerance","mm":"+/-0.5"},{"item":"side, up, down loads","kN":40},{"item":"rear face height tolerance","mm":"+/-2"}]}},{"id":"cell-openings-recesses","kind":"rule","tier":2,"title":"Openings and recesses allowed in the cell (2026)","summary":"2026 cell: cooling opening 3000 mm2 max each; loom and line openings 7000 mm2 total; sensors 1500 mm2 total; none in the 100 mm structural section. Recesses: 8000 mm2 per SIS, 50000 mm2 for halo front, 75000 mm2 per side at 1.5 mm depth for bodywork.","applies":["survival cell"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.2.4, C12.2.5. Recess steps up to 3 mm deep avoid the 25 deg normal rule. Machined datum details are required on the cell (C12.2.8).","sources":["fia-2026-c21"],"tags":["opening","recess","datum"],"value":{"table":[{"item":"cooling duct each","max_mm2":3000},{"item":"loom and pipe total","max_mm2":7000},{"item":"sensors total","max_mm2":1500},{"item":"SIS recess each","max_mm2":8000},{"item":"halo front recess","max_mm2":50000},{"item":"bodywork recess per side","max_mm2":75000,"max_depth_mm":1.5}]}},{"id":"fuel-bladder-mounting","kind":"rule","tier":2,"title":"Fuel bladder and its fittings (2026)","summary":"2026 bladder: FT5-1999 rubber, 1.0 barG max, life 5 years, inside Y 450. Apertures 35000 mm2 total; bolt-hole edge at least 5 mm from ring edge; clamp area at least 600 mm2. Bladder fixing must fail first: pull-out 11 kN at 1650 mm2 to 37.5 kN at 9500 mm2.","applies":["fuel cell","fuel tank"],"basis":"SRC: FIA 2026 Section C Iss 21 C6.1, C6.2. A fitting under dia 35 mm may use a single fastener with mechanical secondary locking; all others need multiple fasteners on bonded bolt rings.","sources":["fia-2026-c21"],"tags":["fuel","bladder","clamp"],"value":{"table":[{"clamp_mm2":1650,"pullout_kN":11},{"clamp_mm2":9500,"pullout_kN":37.5},{"item":"bolt-hole edge distance","min_mm":5},{"item":"aperture total","max_mm2":35000}]}},{"id":"suspension-pickups-cell","kind":"rule","tier":2,"title":"Suspension pick-ups on the cell and front pairs (2026)","summary":"2026: 6 members per upright; pick-ups behind XC -1580 show no cell damage at 1.25x member compressive failure load; front non-steering, non-rocker members form 2 pairs with inboard points 300 mm apart in X, above Z 250. No rear member on the power unit.","applies":["wishbone","survival cell"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.3. EST: the 1.25x case makes the cell insert stronger than the member, so the member is the fuse.","sources":["fia-2026-c21"],"tags":["pick-up","insert"],"value":{"table":[{"item":"members per upright","count":6},{"item":"failure load factor at mount","ratio":1.25},{"item":"pair X spread","min_mm":300},{"item":"pair height","min_z":250}]}},{"id":"am-chassis-insert","kind":"feature","tier":2,"title":"Printed titanium chassis insert: a published Class A part","summary":"Sauber C41 front lower insert: AM Ti6Al4V Gd 23, about 110x100x130 mm, 580 g, bonded in the laminate. Designed for 200,000 cycles at 65 kN tension and 30 kN compression, plus nose push-off and tether loads. Replaced a multi-piece machined insert.","applies":["insert","wishbone","survival cell"],"basis":"SRC: Additive Industries case study, figures attributed to Kick Sauber. Vendor document, but the only public insert load case found.","sources":["ai-sauber-am"],"tags":["insert","am","titanium","fatigue"],"value":{"table":[{"item":"mass","g":580},{"item":"tension","kN":65},{"item":"compression","kN":30},{"item":"design life","cycles":200000}]},"detail":"Route: non-linear FEA including the bond to the sandwich panel; orient to minimise supports; build simulation adds stiffening ribs because thin walls distort; 50 um layer; tensile coupons in each build; separate laser per insert; HIP; support removal; 2 h tumble; 3D scan against tolerance; coupon tests before release. For CAD: thin bonded flanges with temporary ribs that are machined away. The study also says inserts range across carbon, aluminium and titanium by stress.","see":["materials/ti-6al-4v","turbomachinery/hot-isostatic-pressing"]},{"id":"anti-splinter-laminates","kind":"rule","tier":2,"title":"Prescribed thin laminates: anti-splinter, halo fairing, headrest (2026)","summary":"2026 PL-ANTI-SPLINTER is Type A (over 50% by weight aramid, Zylon, PE, PP or natural fibre), Type B ([B/2, R135, B/2] up to 1000 gsm) or Type C ([C/2, R350, C/2] above). PL-HALO [KC60, CC100, KC60], headrest [KC60, KC60]. FW endplate uses it.","applies":["bodywork","halo fairing","endplate"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.5.1, C15.5.2, C3.19. Thickness of the ply stack is not given, so derive it from the prepreg sheet.","sources":["fia-2026-c21"],"tags":["anti-splinter","laminate","aramid"],"value":{"table":[{"type":"A","reinforcing":"over 50% non-carbon by weight"},{"type":"B","max_gsm":1000,"interlayer":"R135"},{"type":"C","min_gsm":1000,"interlayer":"R350"}]}},{"id":"zpin-and-composite-materials","kind":"material","tier":3,"title":"Polymer composite materials permitted (2026)","summary":"2026 matrices include epoxy, cyanate ester, BMI, phenolic. Fibres: PAN carbon, aramid, PBO, PE, PP, E/S/Q/BF glass, flax, hemp and others. Cores: Al, meta- and para-aramid honeycomb, foam, syntactic, balsa. Z-pinning allowed. 8 matrix items and 7 fibre groups listed.","applies":["composite","carbon part"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.2.3, C15.4 n. Fibre limit example given in the rule: up to Toray T1100 or Mitsubishi MR70.","sources":["fia-2026-c21"],"tags":["prepreg","core","z-pin"],"value":{"options":["epoxy","cyanate ester","bismaleimide","phenolic","polyurethane","polyester","thermoplastic"]},"see":["composites/mat-honeycomb-aluminium","materials/composite-cf-epoxy"]},{"id":"pattern-and-tooling-block","kind":"process","tier":2,"title":"Patterns: epoxy tooling block, 5-axis milled, sealed","summary":"Patterns are milled in 5 axes from epoxy block, not metal, to limit expansion in cure. One 700 kg/m3 board is rated to 130 C, enough for intermediate tools. Reported accuracy +/-0.05 mm. Renault added a 7 m tall machine for floor and tub patterns.","applies":["pattern","tooling"],"basis":"SRC: F1 Chronicle, F1i, Easy Composites EB700 datasheet. Board grade is an example, not a team choice; higher-temperature boards exist. Pattern tolerance is a trade source claim.","sources":["f1chronicle-how-made","f1i-production","ec-eb700"],"tags":["tooling board","pattern","cte"],"value":{"max":130,"unit":"C","note":"service limit of one epoxy board, SG 0.70"},"see":["composites/master-pattern","composites/tool-material-cte"]},{"id":"mould-choice","kind":"process","tier":2,"title":"Mould type follows size, closure, accuracy and time","summary":"McLaren moulds are carbon tooling prepreg on block, rapid-prototype material, or machined polished aluminium, chosen by part size, open or closed, accuracy and time. Printed FDM tools suit some low-load parts; one tooling software vendor claims 3-day mould lead.","applies":["mould","tooling"],"basis":"SRC: CompositesWorld 2020, team interview and supplier claim. Printing polymers limit high-load use. RTM described there as unviable on cost and lead time.","sources":["cw-f1-2020"],"tags":["mould","fdm","aluminium"],"value":{"typical":3,"unit":"text","note":"days, average lead from one tooling software vendor"},"detail":"Prepreg is frozen for 12 months or more. Layup remains by hand with ply nesting software and laser placement. McLaren has about 130 people on composite parts at any one time across clean room, trim, pattern shop and machine shops; Haas outsources to suppliers with about 200 people at peak. 60% scale parts are made for the tunnel with the same process family. Composites are about 80% of the car by volume. The article gives no ply count, parts per season or autoclave count.","see":["composites/tool-draft-release","composites/prepreg-storage-life"]},{"id":"ply-cutting-and-kit","kind":"process","tier":2,"title":"Ply cutting and kitting: the scale of the ply book","summary":"R24 chassis upper part: up to 500 cut shapes, digitised and cut on Lectra, 2-3 h of cutting, up to 5 material types, 10 dedicated laminators on shifts laying 2 chassis at once. Alpine quotes 7 days round the clock and hundreds of pieces for a front wing.","applies":["ply book","chassis","front wing"],"basis":"SRC: Motorsport.com 2003; Driver61 on Alpine. Old and single team. Each ply is checked and counted before the next goes on (F1 Chronicle). Plies need a flat pattern, so flatten double-curved skins first.","sources":["motorsport-r24-composites","driver61-alpine-fw","f1chronicle-how-made"],"tags":["ply","cutting","lead time"],"value":{"max":500,"unit":"count","note":"cut shapes, upper chassis part, Renault 2003"},"see":["composites/process-cut-kit-project","composites/drape-shear-limit"]},{"id":"design-software-ply-book","kind":"note","tier":3,"title":"Ply book is authored from CAD","summary":"Software generates the ply-by-ply guide, updates it when the design changes and warns of wrinkling on curves before production. So store plies against surfaces; keep a surface per ply zone and run drape analysis.","applies":["ply book","cad"],"basis":"SRC: F1i describes it for Renault. EST: the storage advice is our reading of that workflow.","sources":["f1i-production"],"tags":["fibersim","drape","ply book"]},{"id":"production-scale","kind":"note","tier":2,"title":"Production scale: published counts vary","summary":"Formula1.com gives circa 15,000 bespoke components per modern car, built and stripped several times a week; most teams track each part, spare and use history in software. Other counts differ on what is a component. Monaco rear wings run to 4 or 5 sets for a team.","applies":["bom","parts list"],"basis":"SRC: Formula1.com; Autosport for spares. Higher press counts could not be opened, so are omitted. Team totals are unpublished.","sources":["f1-williams-vowles","autosport-upgrades"],"tags":["part count","traceability"],"value":{"typical":15000,"unit":"count","note":"bespoke components per car, circa"}},{"id":"post-cure-machining","kind":"process","tier":2,"title":"Post-cure machining sets the real datums","summary":"After cure, halves go in jigs on a large CNC: holes pass through carbon into metal inserts for pick-ups and engine mounts; 2003 Renault used 2 machines. Leave stock on inserts and put hard-point tolerance on the machined bore, not the moulded surface.","applies":["survival cell","insert"],"basis":"SRC: Motorsport.com 2003 for sequence. EST: the stock advice follows from that sequence. No published tolerance found.","sources":["motorsport-r24-final"],"tags":["machining","datum","insert"],"value":{"typical":2,"unit":"count","note":"machines named on the Renault line"},"see":["composites/drilling-exit-delamination","standards-testing/test-dimensional-inspection-cmm"]},{"id":"physical-tolerance-context","kind":"tolerance","tier":2,"title":"Tolerance anchors in the F1 rules (2026)","summary":"2026 plank +/-0.5 mm form, 10 +/-0.2 thick; rear impact +/-0.5; wheel lip OD +/-0.5, lip thickness +/-0.2; physical bodywork checks allow +/-3 mm. Cooling holes held under 0.2 mm (Brembo). Use these as the only public F1 tolerance marks.","applies":["tolerance","inspection"],"basis":"SRC: FIA 2026 Section C Iss 21 C3.3.2, C3.6.1, C13.7.1, C10.7.2; CompositesWorld for holes. Team drawing tolerances are unpublished.","sources":["fia-2026-c21","cw-brembo-2025"],"tags":["tolerance","cmm"],"value":{"table":[{"part":"plank thickness","mm":"10 +/-0.2"},{"part":"plank form","mm":"+/-0.5"},{"part":"RIS form","mm":"+/-0.5"},{"part":"disc cooling hole","mm":"under 0.2"},{"part":"bodywork physical","mm":"+/-3"}]}},{"id":"inspection-path","kind":"process","tier":2,"title":"Inspection and re-life of carbon parts","summary":"Parts get dimensional checks and NDT, with destructive tests to failure in development. Composite parts are checked out of autoclave and again after each race; front wings are rechecked for stiffness after set mileage. 2 stages, so leave access for probes and NDT.","applies":["inspection","wing"],"basis":"SRC: Autosport and F1 Chronicle. Neither gives sampling, method detail or mileage. EST: the access advice.","sources":["autosport-upgrades","f1chronicle-how-made"],"tags":["ndt","stiffness","lifing"],"value":{"typical":2,"unit":"count","note":"at least post-cure and in-service"},"see":["composites/test-ultrasonic-cscan"]},{"id":"deflection-rig-note","kind":"test","tier":2,"title":"Deflection rigs: tested parts must be linear-elastic (2026)","summary":"FIA bodywork tests use pads and adaptors such as FW 1000 N per side and rear wing 2x[218,0,-985] N, 6 mm and 1.0 deg max. Rule requires nominally linear-elastic parts up to track load, so leave rig adaptor locations and do not rely on stops or gaps.","applies":["wing","floor"],"basis":"SRC: FIA 2026 Section C Iss 21 C3.18 as logged in the house record. Rig detail FIA-F1-DOC-050 is not public. Full table lives in staging/f1-2026/research/cad-requirements.md.","sources":["fia-2026-c21"],"tags":["deflection","rig","flexi wing"],"value":{"table":[{"part":"FW bodywork","N":1000,"max_mm":15},{"part":"RW bodywork","N":"218/985","max_mm":6,"max_deg":1},{"part":"FW flap","N":60,"max_mm":10},{"part":"RW skins","N":60,"max_mm":2}]}},{"id":"pushrod-specimen","kind":"dimension","tier":2,"title":"Composite push-rod: a published section and layup","summary":"University F1-type push-rod: 650 mm long, 38x18 mm aerofoil, wall 1.825-2.45 mm, 2 woven plus 9 to 14 UD plies, failed at 28.75-31 kN in compression, mostly at the pin end. Strength was well below material, so reinforce ends and check buckling.","applies":["push rod","wishbone"],"basis":"SRC: Curley, Mallon, Gilchrist (UCD). Research specimens, not team parts; ply stack reads 0.35 woven, 0.125 UD. Their failures locate at end fixtures.","sources":["curley-pushrods"],"tags":["push rod","layup","buckling"],"value":{"table":[{"item":"length","mm":650},{"item":"section","mm":"38 x 18"},{"item":"wall","mm":"1.825-2.45"},{"item":"failure","kN":"28.75-31"},{"item":"layup uniform","seq":"0/90, 0 x9, 0/90"},{"item":"layup tapered","seq":"0/90, 0x7, 90, 0x6, 0/90"}]},"detail":"Made by wrapping prepreg on a hollow silicone mandrel inside a two-part aluminium cavity mould, the mandrel expanding in cure; 90 min at 125 C and 700 kPa, 2.3 C/min ramp, pressure ramp 50 kPa/min. Mandrel ruptured on removal after three parts; a sand-filled nylon tube replaced it, and a first-ply overlap then starved one part of consolidation. EST lesson for CAD: closed tube sections need a removable mandrel and a mouth at least as large as the section. Laminate Exx 211 to 221 GPa. Deviation from linear at about 90% of failure."},{"id":"tube-bonded-fitting-rule","kind":"rule","tier":2,"title":"Tube with bonded metal end fitting: how to detail it","summary":"EST detail: spigot OD = tube ID minus 2x0.15 mm bondline, bond length about 1.5x OD, rounded spigot entry, a shoulder that bears on the tube end, and a threaded bore for the rod end. Taper the spigot wall where it ends so stiffness steps gradually.","applies":["wishbone","push rod","track rod"],"basis":"EST: engineering judgement, no published number. SRC anchors: Honda RA106 chassis titanium mounts were chemically treated for bonding (HPM 2012, one chassis); FIA C13.5.1 requires an abutment on side-impact-structure bonded mountings only. Test the actual joint.","sources":["hpm-composites-2012","fia-2026-c21"],"tags":["bond","end fitting","rod end"],"value":{"typical":1.5,"unit":"ratio","note":"EST bond length to OD"},"see":["composites/bonded-lap-joint","composites/surface-prep-bond","materials/ti-6al-4v"]},{"id":"wing-push-off-and-fixings","kind":"rule","tier":2,"title":"Wing fixings and endplates (2026)","summary":"2026 FW endplate fasteners and inserts sit at least 30 mm rearward of the leading edge; endplate uses PL-ANTISPLINTER; metal parts must not risk others. FIS wing section test: 2 pads of 3.2 kN down + 2.2 kN rearward at Y +/-250, no failure of the attachment.","applies":["front wing","gurney","endplate"],"basis":"SRC: FIA 2026 Section C Iss 21 C3.19, C13.6.3 b. Wing inserts must carry that push-off.","sources":["fia-2026-c21"],"tags":["fixing","insert","wing"],"value":{"table":[{"item":"fastener setback","min_mm":30},{"item":"wing pad down","kN":3.2},{"item":"wing pad rearward","kN":2.2},{"item":"pad Y","mm":250}]}},{"id":"wing-pillar-and-floors","kind":"rule","tier":2,"title":"Rear wing pillar and floor limits that shape the laminate (2026)","summary":"2026 pylon Z section area 5000 mm2 max, thickness under 25 mm. Main floor radius 25 mm or more with exceptions to 5 mm; assembly fillets 30 mm max. Split moulds away from those tight radii so the laminate can drape through them.","applies":["rear wing","floor"],"basis":"SRC: FIA 2026 Section C Iss 21 C3.11, floor articles via the house record. EST: mould split advice.","sources":["fia-2026-c21"],"tags":["pylon","floor","fillet"],"value":{"table":[{"item":"pylon area","max_mm2":5000},{"item":"pylon thickness","max_mm":25},{"item":"floor radius","min_mm":25},{"item":"floor fillet","max_mm":30}]}},{"id":"plank-and-skid-rule","kind":"rule","tier":2,"title":"Plank and skid construction, not just its envelope (2026)","summary":"2026 plank SG 1.3-1.45, at most 3 pieces, front at least 900 mm; pockets Z -7 to -0.5, at least 10 mm from edges and holes, fillets R 3 vertical, R 10 in plan. Skids machined from solid Ti6Al4V or 17-4PH (38 HRC max). Fixings M6 or larger, 12.9 or 10.9.","applies":["plank","floor","skid"],"basis":"SRC: FIA 2026 Section C Iss 21 C3.6.2 to C3.6.4. Fastener shank must be the weakest link; no skid point over 50 mm from a fastener; no fastener below Z -7.5. Forging, welding or coating skids is banned.","sources":["fia-2026-c21"],"tags":["plank","skid","pocket"],"value":{"table":[{"item":"SG","min":1.3,"max":1.45},{"item":"pocket edge margin","min_mm":10},{"item":"pocket radius vertical","min_mm":3},{"item":"pocket radius plan","min_mm":10},{"item":"fastener","min":"M6"},{"item":"fastener plus washer area","max_mm2":500},{"item":"total fastener area","max_mm2":10000}]}},{"id":"headrest-seat-fixings","kind":"fastener","tier":2,"title":"Quick-release cockpit fixings (2026)","summary":"2026 seat: at most 2 vertical fastenings, without tools or with a 4 mm hex key. Headrest: quick release at each front corner and pegs that stay engaged at 700 x mass N. Driver exit with wheel removed in 7 s, and wheel back within 12 s total.","applies":["seat","headrest","steering wheel"],"basis":"SRC: FIA 2026 Section C Iss 21 C12.5, C12.6, C12.8, C13.9. Steering wheel release is a concentric pull flange behind the wheel.","sources":["fia-2026-c21"],"tags":["quick release","fastener"],"value":{"table":[{"item":"seat fastenings","max_count":2},{"item":"key","mm":4},{"item":"headrest load","N":"700 x mass in kg"},{"item":"exit","s":7},{"item":"replace wheel total","s":12}]}},{"id":"bodywork-quick-fasteners","kind":"note","tier":3,"title":"Bodywork panel fasteners: no published F1 spec found","summary":"Search found no team or FIA numbers for quarter-turn fasteners on F1 bodywork. Only forum posts and catalogue pages. Use hardware pack sizes, add bonded metal receptacles, and call it an assumption.","applies":["bodywork","dzus"],"basis":"EST: no usable source; recorded so an agent does not invent one.","sources":[],"tags":["dzus","gap"],"see":["hardware/safety-and-locking"]},{"id":"am-material-list","kind":"material","tier":2,"title":"Additive metals allowed in F1, including the 60% rule (2026)","summary":"2026 AM alloys: AlSi10Mg, AlSi7Mg, CL-30AL, A20X and others; Scalmalloy, HRL 7A77; Ti Gr1, Gr2, Ti6Al4V, ELI, Ti5553, Ti6242; 316, 304, MS1, 15-5, 17-4; 625, 718, CoCr. Finished mass must be at least 60% of printed mass, excluding supports.","applies":["am","3d print","upright","brake duct"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.2.2. Practical effect: printed parts cannot be mostly machined from a billet-like blank. Standards list is in FIA-F1-DOC-114 (not public).","sources":["fia-2026-c21"],"tags":["additive","titanium","scalmalloy"],"value":{"min":60,"unit":"%","note":"finished mass as a share of printed mass, supports excluded"},"see":["materials/print-process-material-matrix"]},{"id":"scalmalloy","kind":"material","tier":2,"title":"Scalmalloy: LPBF Al-Mg-Sc named in F1 rules","summary":"Scalmalloy, density 2.67 g/cm3: vendor sheet gives about 520 MPa UTS and about 490-500 MPa yield after 325 C for 4 h, then air cool. Listed for F1 AM use in 2026. Specify the stress-relief state and build direction when quoting a strength.","applies":["am","bracket"],"basis":"SRC: 3D Systems datasheet, FIA 2026 Section C Iss 21 C15.2.2 c. Vendor values by parameter set and direction, not allowables.","sources":["3ds-scalmalloy","fia-2026-c21"],"tags":["scalmalloy","lpbf","heat treatment"],"value":{"table":[{"property":"density","value":2.67,"unit":"g/cm3"},{"property":"UTS","value":520,"unit":"MPa"},{"property":"yield","value":"490-500","unit":"MPa"},{"property":"elongation","value":13.1,"unit":"%"},{"property":"stress relief","value":"325 C, 4 h"}]}},{"id":"ti-grades-f1","kind":"material","tier":2,"title":"Titanium grades permitted (2026) and why Gd 23","summary":"2026 wrought or cast Ti list: Gr 5, Gr 23, Gr 9, Ti6242, Ti6246, Ti10-2-3, Ti15-3-3-3, Ti5553 and others. Published safety critical print uses Gd 23 at 50 um layer with HIP. Skids need annealed Ti6Al4V to AMS4928 or AMS4911, 12 alloy groups in all.","applies":["titanium","upright","insert","skid"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.2.1 e, C3.6.3; Sauber study for the build route.","sources":["fia-2026-c21","ai-sauber-am"],"tags":["titanium","grade 23"],"value":{"options":["Grade 5","Grade 23","Grade 9","Ti6242","Ti6246","Ti10-2-3","Ti15-3-3-3","Ti5553","Ti21S","Ti1100"]},"see":["materials/ti-6al-4v","turbomachinery/ti-6al-4v-properties-sourced"]},{"id":"aluminium-magnesium-lists","kind":"material","tier":2,"title":"Aluminium and magnesium permitted (2026)","summary":"2026 wrought Al 1xxx-7xxx under 1% Li plus 2050, 2055, 2099; cast 2xx to 7xx series. Magnesium only WE43B/C, WE54A, AZ80A (rims AZ70 or AZ80). Al-Li callipers are reported by Brembo in 2020; 2050 is a listed Al-Li alloy family member.","applies":["calliper","bracket","casting"],"basis":"SRC: FIA 2026 Section C Iss 21 C15.2.1, C10.7.1; Brembo 2020. EST: linking the calliper to a named grade is not published; Brembo states only aluminium-lithium.","sources":["fia-2026-c21","brembo-2020"],"tags":["aluminium","magnesium","al-li"],"value":{"options":["2050","2055","2099","WE43B","WE43C","WE54A","AZ80A","7075","2618"]}},{"id":"gearbox-case-materials","kind":"material","tier":2,"title":"Gearbox case: published material routes","summary":"Published routes: moulded carbon with Ti reinforcement or bulkheads; cast Ti or Al; printed Ti with carbon sections. Honda RA106 monolithic laminate 2-4 mm with Ti-insert bulkheads, reported 30% lighter and 14% stiffer than aluminium. A 2011 customer unit was about 40 kg.","applies":["gearbox","bellhousing","casing"],"basis":"SRC: HPM 2011, 2012; Autosport 2014; Driver61. Dated, and current team choices are unconfirmed. Carbon cases suffered heat rejection early.","sources":["hpm-gearboxes-2011","hpm-composites-2012","autosport-gearbox-2014","driver61-gearbox"],"tags":["gearbox","titanium","carbon","casting"],"value":{"table":[{"route":"carbon laminate, Honda 2006","wall_mm":"2-4"},{"route":"cast Ti, Minardi 2000","saving":"25% over magnesium"},{"route":"Ti bulkheads and carbon","era":"2011 trend"},{"route":"printed Ti and carbon","source":"Driver61"}]}},{"id":"gearbox-geometry-rule","kind":"dimension","tier":2,"title":"Gearbox internals geometry (2026)","summary":"2026: 8 forward ratios; shafts 90-110 mm apart; gear span at least 175 mm; each pair at least 12 mm wide and 600 g, steel; final drive tip dia at least 205 mm, axis Z 260-280; driveline and shift parts at least 22 kg. Lay out the case round these.","applies":["gearbox","gear"],"basis":"SRC: FIA 2026 Section C Iss 21 C9.5, C9.6. The gearbox is a TRC and also carries RIS and tether loads.","sources":["fia-2026-c21"],"tags":["gear","gearbox","layout"],"value":{"table":[{"item":"shaft centres","min_mm":90,"max_mm":110},{"item":"gear span","min_mm":175},{"item":"gear width","min_mm":12},{"item":"gear mass","min_g":600},{"item":"final drive tip dia","min_mm":205},{"item":"driveline mass","min_kg":22}]},"see":["power-transmission/gearbox-stage-ratio-and-efficiency"]},{"id":"wheel-nut-rule","kind":"fastener","tier":2,"title":"Single wheel fastener and retention (2026)","summary":"2026 wheel fastener: 1 per wheel, OD 105 mm max, axial length 75 mm max, plus dual-stage retention that takes 20 kN axial with thread off and 300 Nm unwind partly engaged, with a visual misfit indicator. Rim test nut torque at least 500 Nm.","applies":["wheel nut","axle"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.9, C13.10. Nut material is not specified in the rule; no team material source opened.","sources":["fia-2026-c21"],"tags":["wheel nut","retention"],"value":{"table":[{"item":"OD","max_mm":105},{"item":"length","max_mm":75},{"item":"retainer axial","kN":20},{"item":"retainer unwind","Nm":300},{"item":"test torque","min_Nm":500}]}},{"id":"wheel-rim-impact","kind":"test","tier":2,"title":"Wheel rim impact test (2026, from ISO 7141:2022)","summary":"2026 rim test: 75 kg striker at 6 m/s or more, 25 +/-1 mm overlap, on outer flange at 13 deg, tyre at 150 +/-10 kPa, nut 500 Nm. Fail: through-fracture of barrel, spokes or hub away from the strike, or over 100 kPa loss in 1 min. Dye penetrant does not count as visible.","applies":["wheel","rim"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.10. EST: the outer flange sees the load, so keep a generous barrel-to-flange transition.","sources":["fia-2026-c21"],"tags":["wheel","impact"],"value":{"table":[{"item":"mass","kg":75},{"item":"speed","m_s":6},{"item":"overlap","mm":25},{"item":"angle","deg":13}]}},{"id":"rod-end-note","kind":"note","tier":3,"title":"Rod ends and spherical bearings","summary":"Rules allow rod ends as a section exception and ceramic spherical bearings as a material exception. No published F1 sizing was found. Assumption: load the rod end axially, use a flexure or spherical in shear where the member bends.","applies":["rod end","wishbone","spherical bearing"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.3.6, C15.4 a. EST: the loading advice is general practice; no rod end size is sourced.","sources":["fia-2026-c21"],"tags":["rod end","flexure"]},{"id":"safety-wire-practice","kind":"fastener","tier":2,"title":"Safety wire practice borrowed from aviation","summary":"FAA AC 43.13-1B and MS33540: 6 to 8 twists per inch, commonly 0.8 mm (0.032 in) wire, pull in the tightening direction, ends bent under and in. Cross-drill bolt heads or use wire tabs, and leave room to reach the next fastener.","applies":["fastener","safety wire"],"basis":"SRC: Wikipedia quoting AC 43.13-1B and MS33540 (FAA PDF returned 403). EST: drilling and reach advice. No FIA or team spec found; FIA asks for mechanical secondary locking in places (C6.2).","sources":["wiki-safety-wire","fia-2026-c21"],"tags":["lockwire","locking"],"value":{"min":6,"max":8,"unit":"text","note":"twists per inch"},"see":["hardware/safety-and-locking"]},{"id":"ndt-penetrant","kind":"test","tier":2,"title":"Dye penetrant inspection of titanium and aluminium parts","summary":"Penetrant finds surface-breaking cracks only, on non-porous metal, with 5-30 min dwell and 10-30 min development. Rough or as-welded faces give false indications, so machine or blend areas to be inspected. ASTM E1417 is the controlling practice named.","applies":["upright","ndt","titanium"],"basis":"SRC: Wikipedia summary naming ASTM E1417; the ASTM page returned 403. I did not read clause contents. Use of penetrant on F1 parts is inferred from general practice and the rim rule mention.","sources":["wiki-dpi"],"tags":["ndt","penetrant","crack test"],"value":{"min":5,"max":30,"unit":"min","note":"penetrant dwell"},"see":["turbomachinery/fpi-inspection-test"]},{"id":"ndt-mpi","kind":"test","tier":2,"title":"Magnetic particle inspection: ferromagnetic steels only","summary":"MPI finds surface and shallow subsurface flaws in ferromagnetic metal only, so it works on steel gears, fasteners and cage tube but not Ti, Al or Mg. Fluorescent method uses UV-A at 365 nm. Demagnetise after. ASTM E1444 is the aerospace practice.","applies":["steel","gear","ndt"],"basis":"SRC: Wikipedia summary naming ASTM E1444; the ASTM page returned 403. Clause contents not read. F1 usage not separately sourced.","sources":["wiki-mpi"],"tags":["ndt","mpi","crack test"],"value":{"value":365,"unit":"text","note":"nm UV-A for fluorescent particles"}},{"id":"lifing-records","kind":"rule","tier":2,"title":"Lifed parts and traceability: published limits","summary":"Published lives: bladder 5 years; Brembo callipers 10,000 km max (2020), about 3 race weekends; Sauber inserts 200,000 cycles for a season. Cells carry 3 FIA transponders. Parts need part number and serial marking space on the model.","applies":["lifing","traceability"],"basis":"SRC: FIA 2026 Section C Iss 21 C6.1.3, C12.2.3; Brembo 2020; Driver61; Sauber study. EST: marking-space advice. Team life tables are unpublished.","sources":["fia-2026-c21","brembo-2020","driver61-brembo","ai-sauber-am"],"tags":["lifing","serial","traceability"],"value":{"table":[{"part":"fuel bladder","life":"5 years"},{"part":"calliper","life":"10000 km"},{"part":"AM chassis insert","life":"200000 cycles"}]}},{"id":"thermal-limit-carbon","kind":"rule","tier":2,"title":"Carbon and thermal limits near hot parts","summary":"Most epoxies start to fail above 150 C; high-temperature grades are quoted over 300 C. Early carbon gearbox cases suffered heat rejection. Near exhausts or brakes, use a higher-Tg resin, a shield or a metal part.","applies":["exhaust","gearbox","brake duct"],"basis":"SRC: HPM 2012, HPM 2011 for numbers. EST: the last sentence. No team Tg or shield spec published.","sources":["hpm-composites-2012","hpm-gearboxes-2011"],"tags":["tg","thermal","heat shield"],"value":{"max":150,"unit":"C","note":"general epoxy failure onset"},"see":["composites/matrix-service-table"]},{"id":"cc-disc-process","kind":"process","tier":2,"title":"Carbon-carbon disc manufacture (Brembo)","summary":"Felt preform in 1-2 mm layers, up to 50 mm thick for some products, carbonised above 1600 C in inert gas, graphitised near 1500 C, methane densified over several cycles with grinding between, graphitised again, F1 above 2000 C for conductivity. Months long.","applies":["brake disc","carbon brake"],"basis":"SRC: CompositesWorld plant tour 2025. A caption there says 200 C for first ovens, which conflicts with 1600 C in the text. Driver61 says up to 3 months blank plus 4 weeks finishing.","sources":["cw-brembo-2025","driver61-brembo"],"tags":["carbon-carbon","cvi","graphitise"],"value":{"min":1500,"max":2000,"unit":"C","note":"graphitisation range quoted"}},{"id":"cc-disc-holes","kind":"feature","tier":2,"title":"Disc cooling holes: counts, rows and accuracy","summary":"F1 discs now about 900-1,100 holes, tolerance under 0.2 mm; peak 1,470 in 2019, falling as the minimum dia rose. Brembo 2020 front options 1480, 1250, 800 holes in 7, 6, 4 rows on 32 mm; rear 1250, 800 in 5, 3 rows on 28 mm. 2026 minimum dia 2.5 mm.","applies":["brake disc"],"basis":"SRC: CompositesWorld 2025; Brembo 2020; FIA 2026 Section C Iss 21 C11.3. Driver61's 3 mm minimum is another era or an error.","sources":["cw-brembo-2025","brembo-2020","fia-2026-c21","driver61-brembo"],"tags":["cooling holes","rows","disc"],"value":{"table":[{"axle":"front 2020","holes":1480,"rows":7,"thick_mm":32},{"axle":"front 2020","holes":1250,"rows":6},{"axle":"front 2020","holes":800,"rows":4},{"axle":"rear 2020","holes":1250,"rows":5,"thick_mm":28},{"axle":"rear 2020","holes":800,"rows":3}]}},{"id":"cc-operating-window","kind":"rule","tier":2,"title":"Carbon brake operating window","summary":"Carbon gives little bite below about 400 C and oxidises beyond about 800 C, though discs exceed 1,000 C briefly (reports to 1,200 C). Size the duct and disc to hold the window, and let a blanking option cover cold circuits. Disc about 1.2 kg, pad 200 g.","applies":["brake duct","brake disc"],"basis":"SRC: Formula1.com for 400/800; CompositesWorld for mass and 1200; Driver61 about 1000 C. EST: duct sizing and blanking advice.","sources":["f1-tech-tuesday-brakes","cw-brembo-2025","driver61-brembo"],"tags":["temperature","oxidation","duct"],"value":{"min":400,"max":800,"unit":"C","note":"working range before oxidation"}},{"id":"brake-usage","kind":"note","tier":3,"title":"Brake parts usage and calliper construction","summary":"Brembo-supplied F1 teams use 140-240 discs and 280-480 pads a season (2025); 150-300 and up to 600 in 2020. Callipers were aluminium-lithium with six pistons; 2026 rule allows up to 4 pairs. Team-specific designs vary.","applies":["brake disc","brake calliper"],"basis":"SRC: CompositesWorld 2025; Brembo 2020; Driver61 for titanium pistons. Supplier-stated.","sources":["cw-brembo-2025","brembo-2020","driver61-brembo"],"tags":["usage","calliper"],"value":{"min":140,"max":240,"unit":"count","note":"discs per team, season 2025"}},{"id":"clutch-note","kind":"material","tier":3,"title":"Clutch: carbon multi-plate, small diameter","summary":"AP Racing lists carbon/carbon clutches from dia 97 mm up to dia 200 mm, in twin, triple and four plate forms, push or pull. Rule allows C/C friction; 2026 clutch paddle travel 80 mm max. No F1 clutch specification found published by a team.","applies":["clutch"],"basis":"SRC: AP Racing range page; FIA 2026 Section C Iss 21 C9.2, C15.4. Link between dia 97 and F1 not confirmed by a source I opened.","sources":["aprc-clutches","fia-2026-c21"],"tags":["clutch","carbon-carbon"],"value":{"options":[97,115,138,140,184,200],"unit":"mm"}},{"id":"dampers-rule","kind":"rule","tier":3,"title":"Inboard suspension elements: what the 2026 rule leaves","summary":"2026: one rocker per wheel; elements rotate only at nodes; springs no fluid medium; gas spring in a damper 10 N/mm max; no coupling or storage. So no hydraulic heave link. Design heave elements as mechanical with clevis nodes on the rocker.","applies":["damper","heave","rocker"],"basis":"SRC: FIA 2026 Section C Iss 21 C10.2, C10.4. Damper internals were not sourced; no team or supplier numbers found.","sources":["fia-2026-c21"],"tags":["damper","heave","rocker"],"value":{"max":10,"unit":"text","note":"N/mm gas spring rate in a damper"}},{"id":"steering-column-test","kind":"test","tier":3,"title":"Steering column impact test (2026)","summary":"2026: 8 kg hemisphere dia 165 at 7 m/s or more into wheel centre, under 80 g beyond 3 ms cumulative, deformation inside the column, quick release still works. So leave a crush length and do not stack hard parts behind the hub.","applies":["steering column"],"basis":"SRC: FIA 2026 Section C Iss 21 C13.8.","sources":["fia-2026-c21"],"tags":["steering","impact"],"value":{"table":[{"kg":8,"m_s":7,"peak_g":80,"dia_mm":165}]}},{"id":"hypercar-contrast","kind":"note","tier":2,"title":"Hypercar LMH and LMDh versus F1","summary":"WEC Hypercar: 1030 kg min, 500 kW max combined, downforce to drag 4:1, BoP adjusted; LMDh chassis LMP2-based from Ligier, Oreca, Dallara or Multimatic; base parts frozen for 5 seasons. So parts live longer: design for life, repair and swap, not one-race weight.","applies":["le mans","hypercar","lmdh"],"basis":"SRC: Motor Sport magazine, not the FIA/ACO text which I did not open. EST: the design-for-life reading. Post-2030 rules differ.","sources":["motorsportmag-hypercar"],"tags":["wec","hypercar","lmdh"],"value":{"table":[{"item":"min weight","kg":1030},{"item":"max power","kW":500},{"item":"L/D","ratio":4},{"item":"LMH hybrid","kW":200}]}},{"id":"gt3-contrast","kind":"standard","tier":2,"title":"GT3: production base, FIA Art 257A (2024 edition)","summary":"GT3 under Art 257A 2024: Ti only if original or authorised; free parts under 40 GPa/(g/cm3) specific modulus; Mg sheet over 3 mm thick only; cage homologated or certified by ASN or FIA; composite chassis repairs by the maker. Reinforce, do not redesign.","applies":["gt3","lmgt3"],"basis":"SRC: FIA Appendix J Art 257A 2024 text, read directly. A 2026 edition exists that I could not open, so check it.","sources":["fia-art257a-2024"],"tags":["gt3","homologation","cage"],"value":{"value":40,"unit":"text","note":"GPa/(g/cm3) limit"}},{"id":"art253-cage-tube","kind":"dimension","tier":2,"title":"Art 253 safety cage tube (2020 edition)","summary":"Art 253-8 2020: cold drawn seamless carbon steel, 350 N/mm2 min; main hoop or lateral 45x2.5 or 50x2.0, other parts 38x2.5 or 40x2.0; round only; bend centreline R 3D or more; ovality ratio 0.9 or more; full-penetration gas-shielded welds; feet 3 bolts on 3 mm, 120 cm2.","applies":["roll cage","safety cage"],"basis":"SRC: FIA Art 253-8 2020, Groups N, A, R-GT. Max 1.7% Mn, 0.6% other elements. Check the current edition: newer cars need homologated or certified cages.","sources":["fia-art253-2020"],"tags":["roll cage","tube","weld"],"value":{"table":[{"use":"main or lateral hoops, rear member","od_x_wall_mm":"45 x 2.5 or 50 x 2.0"},{"use":"other cage parts","od_x_wall_mm":"38 x 2.5 or 40 x 2.0"},{"item":"bend radius","min":"3 x tube OD"},{"item":"ovality minor/major","min_ratio":0.9},{"item":"plate","min_mm":3,"min_cm2":120,"bolts":3}]}},{"id":"weld-4130","kind":"process","tier":2,"title":"TIG welding thin 4130 tube: shop practice","summary":"Shop practice for 4130 under 0.120 in wall: ER70S-2 for ductility or ER80S-D2; no preheat strictly needed though a quick warm is cheap; remove scale, acetone wipe, tack first, cool between runs. CE about 0.44%, so it hardens if quenched. Keep the joint open for access.","applies":["roll cage","space frame","fsae"],"basis":"SRC: Welding Tips and Tricks, a practice source; Art 253 asks to follow the steel maker for heat-treated steel. T45 data sheets could not be sourced: treat T45 as unsupported here.","sources":["wtt-4130","fia-art253-2020"],"tags":["4130","tig","chromoly","filler"],"value":{"max":0.12,"unit":"in","note":"wall below which no preheat, shop figure"}},{"id":"fsae-steel-props","kind":"rule","tier":2,"title":"Formula SAE: properties used for equivalency (2024 rules)","summary":"FSAE SES must use E 200 GPa, Sy 305 MPa, Su 365 MPa for any non-welded steel and Sy 180 MPa, Su 300 MPa for welded, whatever the actual alloy. Main hoop is one piece of steel. A stronger steel gets no credit, so size the section, not the alloy.","applies":["formula sae","fsae","space frame"],"basis":"SRC: FSAE rule F.3.4.2 as republished, 2024 rulebook; Design Judges for 2026 rules. Official PDF not opened. Size A-D tube table was an image, so left out: read the current rulebook.","sources":["fsae-rules-unca","dj-fsae-2026"],"tags":["fsae","ses","tube"],"value":{"table":[{"state":"non-welded","E_GPa":200,"Sy_MPa":305,"Su_MPa":365},{"state":"welded","Sy_MPa":180,"Su_MPa":300}]}},{"id":"fsae-mono-2026","kind":"rule","tier":3,"title":"Formula SAE monocoque practice notes (2026)","summary":"2026 FSAE: two-half tubs need scarf joints with structural adhesive along the full seam; core splices between sections; subframe attachments near nodes; rear bulkhead limit 345 mm cited; module mechanical attachment required in 2027; open-ended pop rivets banned.","applies":["formula sae","fsae","monocoque"],"basis":"SRC: Design Judges summary citing F.7.1.6, F.7.1.7, F.7.8.2, F.11.3.3, F.10.3.2, F.10.1.6. Secondary; laminate test panel numbers were not found.","sources":["dj-fsae-2026"],"tags":["fsae","scarf","splice"],"value":{"value":345,"unit":"mm","note":"rear bulkhead height equivalence limit cited"},"see":["composites/scarf-joint","composites/core-edge-ramp"]},{"id":"formula-e-contrast","kind":"note","tier":3,"title":"Formula E GEN3 versus F1","summary":"GEN3: 840 kg min, no rear hydraulic brakes because regen reaches 600 kW; rear 350 kW plus 250 kW front regen; bodywork uses linen and recycled carbon from GEN2 cars. Spec chassis, so teams detail powertrain, not bodywork.","applies":["formula e"],"basis":"SRC: FIA Formula E GEN3 facts page. EST: last sentence, from spec-car status in press coverage.","sources":["fe-gen3"],"tags":["formula e","gen3"],"value":{"table":[{"item":"min weight","kg":840},{"item":"regen","kW":600},{"item":"rear power","kW":350}]}},{"id":"indycar-contrast","kind":"note","tier":3,"title":"IndyCar aeroscreen versus the F1 halo","summary":"IndyCar aeroscreen from 2020: just over 50 lb with a titanium frame and polycarbonate screen; a 2024 version targeted about 17 lb lighter. A spec part, so teams design round the mounts as with the F1 halo. Tub and IR-18 structure figures were not sourced.","applies":["indycar","aeroscreen"],"basis":"SRC: Motorsport Week 2022. EST: mounts comparison. No IndyCar rulebook opened.","sources":["msw-aeroscreen"],"tags":["indycar","aeroscreen"],"value":{"value":50,"unit":"lb","note":"just over, 2022 report"}},{"id":"regulation-years-note","kind":"note","tier":2,"title":"Numbers in this pack carry a year","summary":"FIA numbers here are Section C Issue 21, 19 Oct 2026, which applies to 2026 and was reissued many times that year. Roll hoop loads, halo loads, disc limits and hole minimum all moved in recent years. Check the current issue before certifying anything.","applies":["all"],"basis":"SRC: FIA 2026 Section C Iss 21; history examples from The Race and Formula1.com. Text was extracted by pdftotext, where article numbers can scramble beside headings.","sources":["fia-2026-c21","the-race-rollhoop","f1-tech-tuesday-halo"],"tags":["regulation","year"]},{"id":"recipe-wishbone-end-insert","kind":"recipe","tier":2,"title":"Recipe: wishbone tube bonded end fitting","summary":"Revolved titanium fitting for a 30 x 26 mm tube: 0.15 mm radial bondline spigot, 40 mm bond length, shoulder at the tube end, tapered spigot tip and a blind M10 rod-end bore.","applies":["wishbone","push rod","track rod"],"basis":"EST: Worked from tube-bonded-fitting-rule; sizes are illustrative, no team drawing exists in public.","sources":["hpm-composites-2012"],"tags":["recipe","insert","bond"],"recipe":{"prompt":"Model a titanium end fitting bonded into a 30 mm OD 26 mm ID carbon wishbone tube, with an M10 rod end bore","steps":[{"tool":"cad_revolve_profile","args":{"profile":[[0,0],[15,0],[15,22],[12,22],[12,24],[12.85,24],[12.85,58],[11,64],[0,64]]},"note":"axis Z: 22 mm rod-end head dia 30, shoulder at Z 22-24, spigot dia 25.7 (0.15 radial bondline in ID 26), 40 mm to tapered tip"},{"tool":"cad_cylinder","args":{"r":4.25,"h":19,"origin":[0,0,-1]},"note":"M10 x 1.5 tap drill dia 8.5, 18 mm deep from the rod-end face"},{"tool":"cad_boolean_subtract","args":{"of":"$0","tool":"$1"},"note":"cut the rod end bore"}],"expect":{"volume":35757.56,"faceCount":11,"watertight":true,"note":"measured 2026-11-04: first pin"}}},{"id":"recipe-disc-cooling-holes","kind":"recipe","tier":2,"title":"Recipe: brake disc cooling-hole pattern plate","summary":"Unwrapped rim coupon of a 32 mm disc, 48 x 32 x 50 mm, with 7 rows at 4 mm pitch of 8 dia 2.5 blind holes at 5.5 mm pitch, 40 mm deep. Use it to check ligaments before a full ring: a whole ring of 1,000 radial holes is a slow kernel call.","applies":["brake disc"],"basis":"EST: Pitch worked from Brembo 2020 (1480 holes, 7 rows, 32 mm) on about dia 330, which gives 4.9 mm; 5.5 mm used here. Holes are unstaggered for the check. Min dia from FIA 2026 Section C Iss 21 C11.3.","sources":["fia-2026-c21","brembo-2020"],"tags":["recipe","disc","holes"],"recipe":{"prompt":"Model a test plate for a brake disc cooling-hole pattern with 7 rows of 2.5 mm blind holes in a 32 mm thick rim","steps":[{"tool":"cad_extrude_profile","args":{"depth":50,"outer":[[0,0],[48,0],[48,32],[0,32]]},"note":"XY is the rim face, thickness 32 in Y; Z is radial"},{"tool":"cad_hole_pattern","args":{"of":"$0","type":"drill","diameter":2.5,"depth":40,"tip":false,"toolMatch":"off","pattern":{"kind":"grid","origin":[5.75,4],"dx":5.5,"dy":4,"nx":8,"ny":7}},"note":"radial blind holes from the +Z rim face: 7 rows of 8"}],"expect":{"volume":65804.43,"faceCount":174,"watertight":true,"note":"measured 2026-11-04: first pin"}}},{"id":"recipe-gurney-strip","kind":"recipe","tier":2,"title":"Recipe: gurney strip with fixings","summary":"A 300 mm long L-section strip, 10 mm tall (the 2026 front wing maximum), 1.5 mm wall, 15 mm flange with five 3.2 mm fixing holes at 60 mm pitch.","applies":["gurney","front wing","rear wing"],"basis":"EST: Height limit from FIA 2026 Section C Iss 21 via the house record; wall, flange and fixing size are illustrative.","sources":["fia-2026-c21"],"tags":["recipe","gurney","fixing"],"recipe":{"prompt":"Model a 300 mm gurney strip with a 10 mm blade, 15 mm flange and five fixing holes","steps":[{"tool":"cad_extrude_profile","args":{"depth":300,"outer":[[0,0],[15,0],[15,1.5],[1.5,1.5],[1.5,10],[0,10]]},"note":"L-section in XY, extruded along Z"},{"tool":"cad_hole_pattern","args":{"of":"$0","type":"drill","diameter":3.2,"through":true,"toolMatch":"off","face":{"normal":[0,-1,0]},"pattern":{"kind":"linear","origin":[8.5,30],"step":[0,60],"count":5}},"note":"fixings through the flange, from the -Y face"}],"expect":{"volume":10514.68,"faceCount":18,"watertight":true,"note":"measured 2026-11-04: first pin"}}},{"id":"recipe-suspension-clevis","kind":"recipe","tier":2,"title":"Recipe: machined suspension clevis","summary":"A 40 x 30 x 36 mm clevis block with a 14 mm slot and a dia 10 cross pin hole, fork lugs 8 mm each side. Machined aluminium or titanium, the node form a rocker or pick-up uses.","applies":["clevis","rocker","pick-up"],"basis":"EST: Illustrative sizes. Node-only rotation follows FIA 2026 Section C Iss 21 C10.4.","sources":["fia-2026-c21"],"tags":["recipe","clevis","machined"],"recipe":{"prompt":"Model a machined suspension clevis with a 14 mm slot and 10 mm cross pin","steps":[{"tool":"cad_extrude_profile","args":{"depth":30,"outer":[[-15,0],[15,0],[15,36],[7,36],[7,14],[-7,14],[-7,36],[-15,36]]},"note":"U-shaped fork section extruded along Z"},{"tool":"cad_hole_pattern","args":{"of":"$0","type":"drill","diameter":10,"through":true,"toolMatch":"off","face":{"normal":[1,0,0]},"pattern":{"kind":"points","points":[[24,15]]}},"note":"pin hole, first lug: a through hole stops at the far side of the wall it enters"},{"tool":"cad_hole_pattern","args":{"of":"$1","type":"drill","diameter":10,"through":true,"toolMatch":"off","face":{"normal":[-1,0,0]},"pattern":{"kind":"points","points":[[24,15]]}},"note":"pin hole, second lug"}],"expect":{"volume":21903.36,"faceCount":14,"watertight":true,"note":"measured 2026-11-04: first pin"}}}]}