In a sport where everything is pushed to its limit, making sure all the components that make up an F1 car are up to surviving the brutal demands of racing is crucial. How's that done? Aston Martin Aramco Stress Engineer Carlos Sánchez Martínez takes us through every element of the job and what it takes to pursue a career in this field.
To maximise performance, every part of an F1 car has to work at its optimum. That's more than 13,000 individual components, all functioning perfectly and in harmony.
But in an environment where the car is clattering across kerbs hundreds of times per race, where regular lateral and longitudinal forces can nudge 6G and in which any incident can send those forces spiralling, making sure those components can withstand the intense shock of Grand Prix racing is essential.
Enter the Stress Engineer, whose job it is to make sure every element of our F1 cars is up to the task, as our own Carlos Sánchez Martínez explains…
What does a Stress Engineer actually do?
"My job is focused on the structure of the car, and we use tools – both hand-calculation and computational tools – for predicting the state of the mechanical components of the car under the different working conditions, be they on track working conditions or through FIA tests or R&D tests.
"We look at the stress and strains on the component, whether the components will be safe for use on the track. If an initial analysis says they won't, we then see how we can solve that, working together with the designers to make them work properly. We also look at the deflections, the stiffness of the components, and take into account the cost of the components now, with the cost cap, and the time constraints we have.
"The structures department is important because it helps to reduce the time it takes from concept to final component. The department reduces the number of iterations of a component by ensuring that whatever we put on the car behaves as intended. And it also plays a key role in ensuring reliability.
One of the most enjoyable aspects of this role is that you don't always focus on the same components of the car.
Carlos Sánchez Martínez, Stress Engineer
"We also do something called a 'mesh'. We 'mesh' the solid CAD model of the component by dividing it into small pieces called elements and then connect everything together to make a 3D or 2D 'mesh' of the component.
"Once we have done that, we decide on the working conditions we want to analyse, such as aerodynamic pressure, inertial forces, temperature. We run the simulation, get the results and then process and analyse them to understand whether the component is behaving as we intended. Finally, we try to validate those results with physical testing to make sure that the initial conditions we put in our model are representative of real life."
What we're looking for
"When we're recruiting Stress Engineers, the ideal candidate is someone with an engineering background. It can be mechanical, aerospace, materials engineering – anything related to the mechanical engineering aspect of machinery.
"They will also need to have some knowledge and experience of Finite Element Analysis (FEA), which is the main tool we use; it's a computer programme that helps us predict the state of a component under stress. It's a bit like black box software: we provide the input, it solves the problem, and it gives you the output, but a Stress Engineer has to really specify the correct input to ensure that the results from the software are representative."
You've got to be hard working and you have to focus on detail because every bolt is important. If one bolt fails, the car could crash.
Carlos Sánchez Martínez, Stress Engineer
You get to see every phase of development
"One of the most enjoyable aspects of this role is that you don't always focus on the same components of the car. It varies during the season: sometimes I'm working with engine system components for cooling the car, sometimes I'm making aerodynamic parts for the floor, brake ducts or even parts of the chassis. You never get bored in this role. It's very varied.
"You get to see all the phases development too, from the original concept to iterating with the designers, manufacturing the part and then testing it in R&D. You see the full process, all the way through to the component going on the car and then you get the data back from the track to validate your models."
You can't be afraid to ask questions
"To be a Stress Engineer, you've got to be hard working and you have to focus on detail because every bolt is important. If one bolt fails, the car could crash. You also cannot be scared to ask questions: you have to be confident in your abilities but also recognise that you're surrounded by so much expertise in the team that your team-mates can help you find the solutions and answers you're looking for."
You will make a difference
"Pressure definitely comes with the role but it's one of the best parts of the job. It can be difficult to manage sometimes – you're always a bit nervous the day before pre-season testing, or the day before the first race of the season, or when you are putting in a new update on the car that you have worked on a lot – but it's also the most rewarding part of the job because you know that the work you do has a direct influence on the car. You know that what you're doing makes a difference."
Whatever your background, wherever you're from, no matter how hard it might seem, you should not let it put you off pursuing a career in the sport.
Carlos Sánchez Martínez, Stress Engineer
It doesn't matter where you're from
"I started watching Formula One by chance. It was a random moment when my dad was just changing channels on TV and I saw Formula One and I was like, 'What's that?' My family didn't have a motorsport background at all. And then Fernando Alonso started his F1 career and that was a very big thing in my home country, Spain. I started really enjoying the races and I started learning about the cars.
"When you are from a country that doesn't have a big culture of motorsport you feel like it's impossible to achieve so one of the best tips I can give to anybody who wants to get a job in F1 is that whatever your background, wherever you're from, no matter how hard it might seem, you should not let it put you off pursuing a career in the sport. All an F1 team is looking for is someone with the right skills and the right attitude: someone who is eager to learn and to keep improving; someone who understands the importance of being a team player."
Experience matters
"In pursuit of my dream to work in Formula One, I chose to study mechanical engineering at university and that's where I also got involved with Formula Student, which was very useful, both technically and personally. Personally, it helped me really understand what it's like working as part of a racing team: all the challenges you have, not only on an engineering level but also with finding sponsors and promoting the team and trying to get people to believe in your project. And on a technical level, it allowed me to get practical experience with the car."
Pushing the limits
So, you want to be a Stress Engineer?
Carlos Sánchez Martínez discusses what it takes to pursue a career as an F1 Stress Engineer.
"I'm very much a family guy. I'm very close to my family and when a couple of family members sadly passed away, I had a moment of reflection where I thought, 'You have one life, so if you have a dream pursue it.' That was part of the motivation to come to the UK to study for a Master's in motorsport. I never gave up. I started applying for jobs until I got the opportunity with the team. It's been five years now: the time has flown by, and I've loved every minute.
"I firmly believe that perseverance is the key to success. You will never achieve anything if you don't try and the more you try, the more possibilities you have. It's a matter of probability. It may take 10 applications, or it may take 100 but at the end of the day, if you just focus on what people are asking for, you will get there."
Working in F1 is special
"For me, it's quite emotional to think that the dream I have been pursuing for 20 years, I get to live it every day. Sometimes people say, 'Don't you just get tired of it?' But even if you are under a lot of pressure and it's one of those days that you don't feel great, you come to the AMR Technology Campus, swipe your access card on the door underneath those iconic Aston Martin wings, the door opens and it hits home that you are living your childhood dream. It's an incredible feeling."
Top tips
0.5
Study engineering subjects in higher education, such as mechanical, aerospace or materials engineering.
1
Gain an understanding and experience of Finite Element Analysis.
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Practical experience is invaluable. Taking part in initiatives like Formula Student can accelerate your professional and personal development.
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Have an eye for detail, a willingness to constantly learn and improve, and don’t be afraid to ask questions or reach out for help. Never give up on your ambition to work in F1 – perseverance is key.
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