Williams has quietly developed a completely new carbon-fibre manufacturing process as part of its efforts to reduce the weight of its 2026 Formula 1 car — and the project was kept so secret that only 19 people inside the team knew about it.

Just seven members of Williams’ design department and 12 people in manufacturing were aware of the new process. Team principal James Vowles said the method is fundamentally different from the traditional approach Williams had used for around 15 years. 

The new manufacturing technique has been used to produce a revised chassis for the FW48, with the component now completed and having passed all the required tests. Crucially, Vowles says the new structure is both lighter and stronger. 

Weight has been a significant issue for Williams during 2026. The team has acknowledged that the FW48 began the season above the desired weight, although its engineers had already completed much of the work required to bring the car below the minimum target. 

However, Vowles insists the objective is not simply to remove carbon fibre and make existing components lighter. Instead, Williams wants to develop new manufacturing techniques that can deliver lighter structures without sacrificing strength or durability.

That makes the project more than a one-off upgrade. Vowles sees the new process as an investment in Williams’ future, allowing the team to learn new production methods that could eventually be applied to future Formula 1 cars. 

With the secret process now proven and the new chassis ready to race, Williams has potentially turned a weight problem into an opportunity to rethink how it builds its cars.