The Challenge Of Running Sustainable Fuels In MotoGP:
How Ducati Measures Cylinder Pressure To Improve Combustion
Running new sustainable fuels without reducing performance requires using precise cylinder pressure measurement.
“From 2027 onward, we’ll have an entirely new engine, with reduced displacement and renewed fuels,” says Marco Magnani, test-bench engineer at Ducati Corse.
Ducati and Kistler collaborate closely in engine development
For more than two decades, Ducati has trusted measurement technology from Kistler for in-cylinder pressure measurement – a critical metric for understanding and optimizing combustion. Over the years, the partnership has continued to evolve, driven by a shared ambition: To generate ever more accurate insights that refine the calibration and validation of high-performance engines. This also includes the next big challenge: The transition towards more sustainable fuels without compromising the technical and sporting DNA that defines every Ducati engine.
Ducati has always been known for high performance and reliability. However, its naturally aspirated, ultra-high-revving engines challenge any measurement technology: Extreme loads and vibration call for sensors that are exceptionally robust and precise, capable of delivering stable data even with irregular combustion or knock events. Over the years, Ducati has adopted a range of Kistler solutions for in-cylinder pressure measurement, moving from customized M5 cylinder pressure sensors to the latest-generation models such as the 6054C, which delivers thermal stability up to 350°C and a frequency response exceeding 100 kHz and captures even very small pressure fluctuations inside the cylinder.
This technological evolution has been supported by close technical collaboration and the joint development of tailored solutions designed to meet increasingly sophisticated testing demands in engine development. “In our test cells, the engines run at exceptionally high speeds,” says Marco Magnani, test-bench engineer at Ducati Corse. “The vibration and pressure levels are extremely intense – a truly demanding environment for any sensing technology.” The data gathered by Kistler sensors enables Ducati to evaluate combustion quality and cycle efficiency, ensuring stable, repeatable performance. The signal quality and thermal stability of the cylinder pressure sensors allow Ducati’s engineers to evaluate key combustion parameters, such as ignition timing and heat-release rate, in real time and help compare the efficiency of different fuels – from conventional to bio-based.
In recent years, the company has expanded its use to endurance testing to understand engine behavior across its entire lifecycle. “Our top priority is ensuring maximum reliability,” says Daniele Beleggia, test-bench engineer at Ducati. “A failure today isn’t just a technical problem – it has a direct impact on brand reputation. That’s why we rely on cylinder pressure sensors that deliver precision at high pressures, which are critical for performance, as well as at low pressures, which are essential for fully characterizing the combustion process.”
In addition to piezoelectric sensors, Ducati also relies on 4017A and 7547A miniature piezoresistive absolute pressure sensors from Kistler. Mounted in the intake and exhaust manifolds, they allow engineers to compare simulation models with real-world data, offering a clearer and more dynamic view of how the engine behaves. This integrated approach has improved consistency between simulation and reality, giving development teams concrete parameters to work on.
A clear example concerns exhaust after-combustion events, a phenomenon that once caused valve failures. “We investigated the issue using sensors installed on the exhaust,” Beleggia recalls. “The measurements immediately revealed the problem: The after-combustion events were causing the valves to open uncontrollably, leading them to collide and break.” Thanks to direct measurement, the Ducati team identified the root cause and resolved the issue once and for all. “In that case, the sensor data was decisive,” adds Magnani. The integration of Kistler’s piezoresistive and piezoelectric sensors now enables Ducati to monitor the entire combustion cycle – from intake to exhaust – with continuous, high-precision data, turning those insights into targeted, meaningful development actions.
Designing high-performance engines for sustainable fuels
Alongside the pursuit of ever-higher performance, Ducati is now navigating the transition toward more sustainable fuels – a challenge shared across the entire automotive sector. The goal is to reduce environmental impact without compromising the technical and sporting DNA that defines every Ducati engine. Testing fuels containing sustainable components requires extremely precise measurements to understand combustion dynamics and ensure consistent performance. “Testing a new fuel means analyzing the combustion process, and that requires in-cylinder pressure data. Measurement technology from Kistler naturally support us in these evaluations,” Magnani explains. “From 2027 onward, we’ll have an entirely new engine, with reduced displacement and renewed fuels,” Magnani reveals. “In this phase, Kistler sensors will once again play a crucial role.” The collaboration will advance with new sensor generations that integrate seamlessly with existing acquisition systems and deliver an even deeper level of analysis. The goal remains the same: Turning measurement precision into the knowledge that drives innovation.
Looking ahead: continuing collaborative innovation
The partnership between Ducati and Kistler is rooted in trust and ongoing collaboration between their technical teams. “Among our suppliers, Kistler is one of the few we work with in such an open and direct way,” Beleggia says. “We value how available they are and how fast they react, even when things get complex. Price matters, but the real value of a partnership lies in the quality of the support.” As the industry shifts toward new sustainability standards, Ducati and Kistler share the same vision: to keep innovating, with excellence driving every decision.
About Kistler Group
Kistler is the global market leader for dynamic pressure, force, torque and acceleration measurement technology. Cutting-edge technologies provide the basis for Kistler’s modular solutions. Customers in industry and scientific research benefit from Kistler’s experience as a development partner, enabling them to optimize their products and processes so as to secure sustainable competitive edge. Unique sensor technology from this Swiss corporation helps to shape future innovations not only in automotive development and industrial automation but also in many newly emerging sectors. Drawing on our extensive application expertise, and always with an absolute commitment to quality, Kistler plays a key part in the ongoing development of the latest megatrends. The focus is on issues such as electrified drive technology, autonomous driving, emission reduction and Industry 4.0. Some 2,000 employees at more than 60 facilities across the globe are dedicated to the development of new solutions, and they offer application-specific services at the local level. Ever since it was founded in 1959, the Kistler Group has grown hand-in-hand with its customers and in 2025, it posted sales of 424 million Swiss francs. About 9 percent of this figure is reinvested in research and technology – with the aim of delivering innovative solutions for every customer.
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