Custom Designs

FIA FT5-1999

FIA FT5-1999 standard is the highest in use today.

The FIA FT5-1999 brings together the highest strength materials with the most stringent puncture and tear requirements. ATL manufactures Formula 1 fuel cells to the FT5 standard, as well as fuel cells for other high speed single –seater cars and now the World Rally Championship (WRC) following recent regulation changes.

Our FT5 fuel cells are manufactured using unique DuPont Kevlar fibres that are tightly woven and then impregnated and coated using a revolutionary advanced elastomer, proprietary to ATL.

With its unparalleled durability and superior strength, Kevlar is the ideal material for construction of FT5 fuel cells. Whilst its incredible light weight is of great benefit to a car's performance, equally important is the exceptional flexibility that Kevlar offers ATL's FT5 fuel cells. The pliable nature of ATL's FT5 fuel cells allows for relative ease of installation and removal through remarkably small monocoque apertures.

ATL can also incorporate complex baffle systems and hardware into our FT5 bladders. These baffles are typically constructed materials other than the FT5 homologated material in order to save weight.

The FIA mandates that FIA FT5-1999 approved fuel bladders are used in Formula 1, Formula 2, Super Formula, the Word Rally, and a growing number of additional championships.

Formula One

ATL is proud to have supplied every Formula 1 team for almost 20 years.

The construction of a modern F1 cell is enormously complex, featuring numerous internal baffles and fuel collection chambers. Manufactured by hand, each fuel cell takes weeks of painstaking manual work to complete.

The outer surface of every F1 fuel cell is manufactured from ATL 818-D material and features overlap seams and double-reinforced nut ring apertures and corners. Alloy or carbon composite nut rings and ultra-lightweight fittings are boned or encapsulated into the inner surfaces or baffle panels to provide strong, leak-tight attachment points.

Formula 1 fuel cells are designed to scavenge every last drop of fuel and to be as lightweight as possible, providing absolute performance. ATL uses alternative lightweight fabrics to incorporate intricate internal baffle systems, which serve to keep the car's centre of gravity low and ensure a constant supply of fuel to the engine. 

Every year ATL work closely with the F1 teams to ensure that the space envelope provided for the fuel cell is used effectively to hold the maximum fuel volume possible.

This is achieved through a precise fit with geometric faceting of all shapes, and can also include the forming of some panels using composite tooling to perfectly match the curvature of a chassis. This technique when used effectively can save multiple kilograms over a fully facetted fuel cell, as well as increasing the flexibility of the fuel cell. This technology is open to all of our customers to explore.

ATL's unique construction techniques mean that we can modify, or even repair a fuel cell after use. Formula 1 teams are constantly evolving the design of their cars, and ATL are ready to help when there is lap time to be saved!

Other FT5 Racing Formula

ATL also supply FT5-1999 approved fuel cells for single-seater categories including the Super Formula car in Japan and the long-lifed A1GP.

Just as with F1 cells, ATL's construction methods allow internal features such as fabric, alloy or composite internal collector systems and baffles to be integrated to aid fuel pick-up. 

When an existing FT5 fuel cell goes beyond its FIA mandated lifespan, it can be re-manufactured. Also with historic racing becoming ever more popular, ATL can design and manufacture a new fuel cell to the FT5 or any other FIA standard required.

World Rally Championship (WRC)

ATL now manufacture the fuel cells for every World Rally car from our FT5 material. With ever-increasing speeds and the wild and often dangerous rally stage surroundings, the regulations were amended to include the FT5 requirement from 2018.

As with all ATL fuel cells, these WRC fuel cells are as lightweight as possible and incorporate baffle systems and internal collectors to ensure that every last drop of fuel can be used.