Racecar Engineering

Critical mass

The automotive industry is suffering from ‘autobesity’. How did this emerge, and what can be done about it?

- By FELIX LEACH Concept Cars · Clean Tech · Ecology · Cars · Consumer Goods · Transportation · Economics · Industries · Social Sciences · United Kingdom · Love · Earth · Fédération Internationale de l'Automobile

Motorsport has always been a crucible for innovation; an arena where efficiency, performanc­e and regulation collide under extreme conditions. Yet a quieter, more insidious trend has been unfolding both on the track and on the road: autobesity. Put simply, cars are becoming heavier.

What might once have been dismissed as a by-product of safety improvemen­ts, or technologi­cal progress, has become a central engineerin­g challenge, one with profound implicatio­ns for performanc­e, sustainabi­lity and the future of racing and motoring.

The growth in vehicle mass is not a uniquely motorsport phenomenon. Road cars have steadily gained weight, due to a combinatio­n of factors: enhanced crash structures; larger dimensions; hybrid and fully electric powertrain­s; and consumer preference for SUVs (so-called Sport Utility Vehicles). These same drivers, especially safety and electrific­ation, have translated directly into numerous racing categories.

Unforgivin­g physics

Formula 1 offers a clear illustrati­on: since the introducti­on of hybrid power units in 2014, minimum car weight has risen dramatical­ly.

The addition of energy recovery systems and increasing­ly robust safety structures, such as the Halo, has pushed cars well beyond their historical norms. In addition, larger cars provide better aerodynami­c platforms – albeit at the cost of more challengin­g overtakes. Similar trends can be observed in endurance racing, Formula E, and even some junior categories.

Of course, this weight gain is not without consequenc­e. Engineers instinctiv­ely understand that mass is the enemy of performanc­e. It increases inertia, reduces responsive­ness and places greater demands on tyres, brakes and energy systems. But the implicatio­ns extend far beyond lap time.

At its most fundamenta­l level, the relationsh­ip between mass and energy is unavoidabl­e. Moving a heavier object requires more work, more work requires more energy, and more energy, whether derived from a liquid fuel or electricit­y, implies greater environmen­tal impact. This is not merely a theoretica­l construct. Even in highly optimised systems, the laws of physics impose limits that no amount of engineerin­g ingenuity can fully overcome. In motorsport, this manifests in multiple ways:

What might once have been dismissed as a by-product of safety improvemen­ts, or technologi­cal progress, has become a central engineerin­g challenge

• Fuel or energy usage increases with mass, a ecting stint length and strategy.

• Tyre degradatio­n accelerate­s under higher loads.

• Braking systems must dissipate more kinetic energy, increasing wear and temperatur­es.

• Cornering performanc­e su ers due to higher lateral loads and inertia.

These are not independen­t e ects, they compound one another. A heavier car requires stronger components, which also add weight, a feedback loop engineers are constantly battling.

Beyond conjecture

As I expand on in my recent book, Critical Mass, co-authored with Nicholas Molden, energy consumptio­n is intrinsica­lly linked to mass, but so is much else. We argue that the environmen­tal impact of a vehicle can be best approximat­ed by the product (multiple) of vehicle mass and distance travelled. We call this the Molden-Leach Conjecture.

It’s a bold claim, but one that is grounded in extensive analysis. Vehicle mass correlates strongly with the following:

• Energy consumptio­n, and hence CO emissions

• Lifecycle emissions

• Non-exhaust emissions (for example, tyre and brake wear)

• Infrastruc­ture impact

• Noise

• Safety externalit­ies

Indeed, 83 per cent of regulated pollutants that remain problemati­c are strongly linked to car weight.

Electri cation has been heralded as a solution to environmen­tal concerns, both in road transport and motorsport. Yet it introduces a paradox: while electric powertrain­s can be highly e cient, they are also inherently heavy. Battery systems, even with ongoing improvemen­ts in energy density, remain signi cantly heavier than equivalent energy storage approaches.

In Formula E, for example, the battery pack represents around 37 per cent of total vehicle mass in Gen3. In F1 and endurance racing, hybrid systems add signi cant complexity and weight, even as they improve e ciency.

The bene ts of electri cation are immense, but we must not be blind to the costs. In recent years, we have spent a lot of time thinking about choosing technologi­cal solutions, rather than thinking more holistical­ly. For motorsport and automotive engineers, this raises a critical question: are we optimising the right variable?

Hidden costs

The e ect of vehicle mass on its environmen­tal impact extends far beyond tailpipe emissions. This is especially relevant in motorsport, where the focus is often on fuel e ciency or energy recovery.

Non-exhaust emissions, such as tyre wear, brake dust, and road surface degradatio­n are increasing­ly recognised as signi cant contributo­rs to global air pollution. These e ects scale directly with vehicle mass.

We argue that the environmen­tal impact of a vehicle can be best approximat­ed by the product (multiple) of vehicle mass and distance travelled. We call this the MoldenLeac­h Conjecture

Heavier cars generate more particulat­e matter, regardless of powertrain. This is particular­ly true in a world where internal combustion engine vehicles have lters at the tailpipe, near eliminatin­g this as a source of these emissions.

Similarly, noise and safety impacts are strongly in uenced by mass. Larger, heavier vehicles carry more kinetic energy, increasing the severity of collisions. While crash structures in the vehicle increase protection for the occupants, the impact on things the vehicle hits increases substantia­lly with mass. Indeed, this is a classic ‘externalit­y’ problem: something that may bene t the individual (eg increased safety or performanc­e) but imposes costs on society.

Where does it end? Is the safest vehicle for me and my family a tank?

The impacts on our infrastruc­ture are perhaps the most noticeable, but least connected to vehicle weight. Increasing potholes, closed bridges and essential upgrades to

If we can align lighter racecars with lighter road cars, then ‘race on Sunday, sell on Monday’ will have a new impetus, and open a new avenue in consumer innovation and amenity

multi-storey car parks are all in part due to the increases in vehicle weight we see everywhere. Not just with EVs.

Finding it harder to fit in a parking space? Unsurprisi­ng, because the cars we drive have become bigger. Without our roads and car parks growing, there is simply less space for them. This is perhaps best illustrate­d by the fact that in the UK, the ‘standard’ highway width is 7.5m. This was easily enough for two parked cars and two passing cars 100 years ago. Today, it’s barely enough for a single passing car with two parked cars.

This is analogous to the larger motorsport cars today having better aerodynami­c platforms, but being much harder to pass.

The vast majority of racetracks have not been made wider!

Complexity vs simplicity

Modern motorsport regulation­s are complex, reflecting the multifacet­ed nature of performanc­e and sustainabi­lity. Fuel flow limits, energy recovery caps, Balance of Performanc­e (BoP), and cost caps all attempt to balance competitio­n with efficiency. One approach would be to bring in increased incentives to optimise for mass alongside these (though the lap time penalty for being overweight is already pretty severe).

But what if, instead of increasing complexity further, we simplified? Is there a world where simpler regulatory approaches, focusing more on mass, could be more effective? They might have the side benefit of being easier to understand as well!

Such approaches would not eliminate the need for other regulation­s, but could provide a clearer direction for engineerin­g developmen­t in the future.

On the road regulation can help too, and now is the time. Petrol tax is beginning to run out of steam as electrific­ation of road cars becomes a reality. Love it or hate it, government­s around the world are not going to want to give up such a lucrative source of revenue.

So, a taxation based on the product of vehicle mass and annual distance travelled (which could be picked up at the car’s annual service) is an attractive alternativ­e to things like road pricing, which brings substantia­l privacy concerns, or taxing electricit­y for vehicles, which has practical challenges. This could be done in a revenue neutral way and phased in as the proportion of electric vehicles increases.

Leadership opportunit­y

Historical­ly, motorsport has led the way in automotive innovation; from aerodynami­cs to hybridisat­ion. The current moment presents another opportunit­y for leadership. Motorsport plays an immense role in shaping broader trends, and the number of eyeballs it attracts each week is outstandin­g. By prioritisi­ng lightweigh­t design and efficiency, racing can set an example for the wider industry.

The FIA’s ‘nimble car’ concept, which is at the heart of 2026 F1 technical regulation­s, is a step in the right direction. Let’s now follow this path in other series, as well as in the next iteration of grand prix cars.

This is not without precedent.

The fuel crises of the 1970s drove significan­t reductions in vehicle weight and improvemen­ts in efficiency. Motorsport responded with innovation­s that eventually filtered down to road cars. Today’s challenge is different, but no less urgent. Energy markets, climate change, resource constraint­s, safety, infrastruc­ture and regulatory pressures are rapidly reshaping the automotive landscape. Motorsport must decide if it follows or leads.

It would be naïve to suggest that reducing mass is straightfo­rward. Many of the factors driving weight increase, particular­ly occupant safety, are non-negotiable. Crash structures, driver protection systems and robust components are essential. Similarly, hybrid systems and electrific­ation bring performanc­e and efficiency benefits that cannot be ignored. Or certainly are not being ignored.

The challenge, therefore, is to innovate while preserving these benefits. Areas where such innovation could occur include: lightweigh­t materials (composites, alloys); advanced manufactur­ing processes (AM, for example); aerodynami­cs (including active aero) to enable smaller platforms; battery innovation­s; and, ultimately, integrated systems thinking. In addition, the ‘soft power’ of motorsport should be brought to bear, reversing current fashions that indicate bigger is better.

The best news of all is that this can all be done. The McMurtry Spéirling is leading the way. This small, battery electric vehicle, weighing only 900kg, holds both the Goodwood Festival of Speed hillclimb record and the Top

Gear test track record. It’s a very impressive piece of engineerin­g.

Reframing the problem

For decades, motorsport engineerin­g has been defined by the pursuit of marginal gains; finding minute performanc­e improvemen­ts in ever more complex systems. We have lost sight of mass in the regulation­s and in society, yet it is a dominant factor in both performanc­e and environmen­tal impact.

Consequent­ly, it demands a central place in engineerin­g decision making. We must refocus our innovation, and motorsport should lead the way. If we can align lighter racecars with lighter road cars, then ‘race on Sunday, sell on Monday’ will have a new impetus, and open a new avenue in consumer innovation and amenity.

Motorsport has always thrived on clear objectives: go faster, last longer, win. Now it is time to add another: weigh less. We need to put all of our cars on a diet.

Dr Felix Leach is an associate professor of engineerin­g science at University of Oxford. With Nick Molden he co-authored the book Critical Mass: The One Thing You Need to Know About Green Cars, published in 2024.

What if, instead of increasing complexity further, we simplified? Is there a world where simpler regulatory approaches, focusing more on mass, could be more effective?

 ?? ?? The battery pack in a Gen4 Formula E racer accounts for approximat­ely one third of the car’s overall weight, making it significan­tly heavier than other powertrain options
The battery pack in a Gen4 Formula E racer accounts for approximat­ely one third of the car’s overall weight, making it significan­tly heavier than other powertrain options
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 ?? ?? Fig 1: Vehicle weight trends for various motorsport series (above) and for road cars in various European countries (below)
Fig 1: Vehicle weight trends for various motorsport series (above) and for road cars in various European countries (below)
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 ?? ?? Autobesity by era. Average road car size has steadily increased, yet the infrastruc­ture they travel on remains largely unchanged
Autobesity by era. Average road car size has steadily increased, yet the infrastruc­ture they travel on remains largely unchanged
 ?? ?? Cars like the British McMurtry Spéirling PURE 3 are showing the way for small, light racecars with huge potential, flying in the face of the ‘bigger is better’ trend
Cars like the British McMurtry Spéirling PURE 3 are showing the way for small, light racecars with huge potential, flying in the face of the ‘bigger is better’ trend

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