The process of building an F1 car is both lengthy and complex, with the entire cycle from the initial conceptualization of the design to the final first test drive usually taking between six and ten months to complete. Computers play a vital role in this process, and through the use of advanced computer simulation software, engineers are able to accurately estimate and predict the performance of the car. Nonetheless, in modern manufacturing plants that are capable of producing the majority of components on their own, machines still cannot fully replace human skill and experience. To ensure that the secrets of the design and manufacturing process are not compromised, the drawing rooms and workshops of the cars are closely guarded, like banks, surrounded by walls and regularly inspected by security guards. At night, these areas are lit up to ensure security and confidentiality.
Building an F1 car requires the combined efforts of a team of top-notch technicians, including the Technical Director, Design Office Manager, Race Engineer, Director of Composites, Machinist, Head of the Machine Shop, Electrical Engineer, Paint & Decorator, Aerodynamic Engineer, and many more. The Technical Director plays a vital role in this team and is known as the true “Father of the Race Car”, directing and coordinating the work of all departments as the overall commander. Before officially manufacturing the car, the engineers will first make a scaled-down model and test it in a wind tunnel to simulate the wind speed when the car is traveling at 300km/hour on a race track, which will serve as a reference for designing the real car.
The production process of a racing car can generally be divided into six main stages: firstly, the car shell made of laminated carbon fiber is roasted in a vacuum furnace before painting; secondly, the assembled engine is securely mounted at the rear of the car; thirdly, the side hatch covers of the shell are fitted with cooling grids; fourthly, the assembled gearbox is connected to the engine to make a single unit; and fifthly, the cross-arms are installed, suspension, brakes and rear drive; and finally, in the sixth stage, the wing panels, bodywork and wheels are fitted. At this point, the race car is finally ready to start. However, the electronic management systems for the gearbox and engine are usually left until just before the car is due to start.