Testing Formula 1® transmission systems is an extremely complex and demanding
challenge. Over the past few years, AVL RACETECH, the motorsport division of AVL,
has become the market leader in this field – not least thanks to a bold technical
innovation: the F1 Prime Mover. This milestone project not only secured AVL’s
position in motorsport but also laid the foundation for a specialized area of expertise
that now extends into e-mobility, aerospace, and advanced drive train validation.
“Achieving high power density
with low rotor inertia was key
– and only possible through
close cross-disciplinary
collaboration.”
“With our F1 Prime Mover, we have
set new benchmarks at the pinnacle
of motorsport.”
How AVL Took the Lead
in F1 Transmission Testing
t all began in 2017, when the FIA and Formula 1 presented
a roadmap and key features for a new, significantly stronger
power unit to be introduced in 2021. This next-generation
powertrain entailed the development of an equally powerful
gearbox, including testing and validation under realistic condi-
tions. Essential for this task was a prime mover: an electric drive
system capable of accurately replicating the dynamic behavior
of a complete F1 power unit in a gearbox test system.
AVL accepted the challenge and set up a project financed
entirely by internal R&D activities. The goal was to develop a
prime mover that could cover the widest possible range of
operating conditions within a single test environment – while
also supporting future transmission applications in Formula 1
and beyond.
With a peak output of 1,100 kW, high power density, extremely
low rotor inertia, high dynamic response, and thermal stabil-
ity over long test cycles with frequent high-load peaks, the
technical requirements were incredibly demanding. Complete
clean-sheet development was necessary.
Applying a “first time right” philosophy, AVL guided the entire
design process with extensive FEM simulations. Core compo-
nents – such as the electromagnetic layout, rotor/stator design,
and thermal management architecture – were optimized specif-
ically for this use case. Insights gained from the previous F1 V8
Prime Mover were directly incorporated into the new design.
Another critical aspect was proper testing for performance and
durability under F1 conditions, which AVL was able to complete
successfully thanks to its in-house testing capabilities. Final
validation of the system with a real F1 gearbox was carried
out in cooperation with an industry partner. Despite technical
setbacks and intensive design iterations during this phase, the
HANNES GRUBER
Department Manager
Mechanic Development & Innovation
MARTIN MONSCHEIN
Global Business Segment Manager Racing &
Advanced Solutions
AVL Prime Mover
project team’s perseverance ultimately resulted in a ready-for-
market product.
The newly developed prime mover impresses with outstanding
features. Particularly remarkable is the balance between low
rotor inertia and high-power density – achieved through close
collaboration between electromagnetic and mechanical design
teams. Its wide operating range and dynamic response enable
the prime mover to accurately emulate both current and future
F1 power units. It supports test procedures far beyond static
loading – such as transient torque peaks, gearshifts, and launch
simulations – taking testbed realism to a new level.
Since its inception in 2017, the system has been success-
fully deployed in multiple high-end testing environments and
continuously refined. AVL’s system-level expertise, integration
capability, and technological depth proved decisive for the fast
market launch and widespread acceptance. Today, AVL supplies
the majority of installations in the F1-transmission test system
market – and has grown from a niche provider into the market
leader in this highly specialized segment.
2025