"About 80% of the fabrication process is done by hand. The technicians make more than 100 folds, and install joints, inserts and reinforcements. The first custom made fuel cell of a new F1 car may require up to 200 hour/man of work. But after that, each cell will call for 120 hour/man of work to be fabricated."

CAO drawing of the Ferrari F2002 showing the location fo the fuel cell in white.

It is interesting to know that a bladder weighs only 5% of the total mass of fuel it can hold. While the fuel tank is the biggest, single part of the car, it represents only 1% of its total weight.

Each bladder costs about $30,000 to make, to that you must add a few dollars for the development, the research, the design, and the regular inspections. During a typical season, a Formula 1 team can use up to 15 fuel cells in five different cars.

The bladder has pre-determined life expectancy. Once this "mileage" is reached, each bladder is stripped from its internal components (pumps, filters, pipes, sensors, overflow reservoirs, etc), tested at ATL for possible leaks and carefully inspected before it is returned to the team. However, a bladder can never exceed its maximal life limit of seven years.

Front side of the bladder with the notch for the driver's seat.

Photo Credit : ATL, Ferrari & GEPA pictures/ Bildagentur Kraeling