Case Study: How Hydraulic Technologies Helped Power F1 Flywheel Manufacturing

In the high-stakes world of Formula One, milliseconds can mean the difference between the podium and going home empty-handed. Precision is everything. That demand for perfection extends far beyond the track, into the factories where critical components are made.

When a specialized manufacturer faced production bottlenecks while producing carbon fiber flywheels for F1 powertrains, they turned to Power Team for a smarter, more precise solution.

The Challenge: Breaking Through a High-Precision Bottleneck

Carbon fiber flywheels are lightweight, high-performance components at the heart of energy recovery systems in Formula One. Manufacturing them requires:

• Precision Insert Installation – Inserts must be pressed into carbon fiber structures without damaging the delicate composite material
• Control and Consistency – Mechanical fly presses lacked the ability to deliver controlled, repeatable pressure
• Budget Sensitivity – While F1 budgets are high, manufacturers still demand cost-effective tooling
• Compact Floor Layouts – The facility had strict space constraints for any new system
• Zero-Defect Expectations – Repeatable performance was non-negotiable in a Formula One context

The manufacturer needed compact, controlled, repeatable hydraulic force that fit within budget and spatial limits, and compromising on quality is never an option. 

The Power Team Solution: A Compact Hydraulic Pressing System

Hydraulic Technologies worked closely with the manufacturer to deliver a turnkey press configuration based on Power Team components:

System Components:

• SPM256C Frame Press – Engineered for precise force application in controlled environments
  
• 60846 Pedestal – Stable, space-saving mounting platform
• PA6 Air Pump – Pneumatic-powered, compact footprint pump
  
  

Custom Integration Features:

• Customer-Provided Mandrel - Specialized tooling to distribute force evenly across carbon fiber inserts
• Controlled Force Distribution - Hydraulic system ensures consistent pressure application without damaging delicate carbon fiber materials

This setup provided precise, shock-free pressure, reducing damage risk and improving insertion consistency.

Why Hydraulic Technology Was the Right Fit

Precision Force Control

Hydraulic systems apply steady, measured pressure, unlike mechanical presses that deliver abrupt impact. This was essential to protect delicate composites.

Space-Saving Footprint

The vertical configuration of the SPM256C + pedestal delivered press functionality in tight manufacturing layouts.

Cost-Conscious Performance

The PA6 air pump powered the system with no need for complex hydraulics or electric motors, keeping the budget lean while delivering repeatability.

Consistent Quality

Repeatable pressure = repeatable results. This system ensured high-precision insert installs across production runs.

Ready to Bring This Precision to Your Line?

If you're producing carbon fiber components, composite structures, or tight-tolerance assemblies, Power Team’s hydraulic tools and equipment provide the control and consistency modern manufacturers need.

Talk to a Specialist