Ford’s return to Formula 1 racing in 2026 is still a year away, but the company is already deeply involved in testing and development with its partner, Red Bull Racing. The focus is on advanced testing methods, including 3D printing and non-destructive evaluation techniques, to produce high-performance components for the race cars.
Ford has reportedly produced around 1,000 parts for Red Bull using 3D printing technology. These parts include complex metal and polymer components that must withstand the extreme conditions of F1 racing. The 3D printing process allows for the creation of parts with intricate designs that would be impossible to manufacture using traditional methods.
The testing process involves rigorous evaluation of each component. Parts are subjected to tests for mechanical strength, hardness, and geometric compliance. They also undergo X-ray and CT scanning to create digital models for analysis. This level of scrutiny ensures that the parts can withstand the stresses of high-speed racing.
Ford’s expertise in manufacturing and engineering is being leveraged to produce components for the power unit, including both the internal combustion engine and the hybrid system. The company is drawing on the knowledge and experience of employees from various departments, including those involved in vehicle development, thermal systems, and battery technology.
The advanced testing methods used in the F1 program are also benefiting Ford’s consumer vehicle production. For example, the non-destructive testing techniques helped identify a glue overflow issue in the headlamps of the F-150, leading to improved quality control processes.
Ford’s partnership with Red Bull Racing and its focus on advanced testing highlight the company’s commitment to innovation and performance. The knowledge gained from the F1 program is expected to contribute to the development of future Ford vehicles, enhancing their performance, reliability, and efficiency.
