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A flat engine is an internal combustion engine with multiple pistons that all move in the horizontal plane. The most popular and significant layout has cylinders arranged in two banks on either side of a single crankshaft, generally known as "boxers". There is a widely-used but technologically less significant form consisting of a straight engine with two, three, four or more cylinders canted 90 degrees into the horizontal plane.
The concept of the boxer was patented in 1896 by engineer Karl Benz, eight years after he started producing the world's first successful cars. Flat engines are commonly described as horizontally opposed engines but must not to be confused with opposed-piston engines, which are mechanically quite different.
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Flat engines have a lower center of gravity than any other common configuration, so vehicles using them should benefit from better stability and control. They are, however, also wider than more traditional configurations and the extra width causes problems fitting the engine into the engine bay of a front-engined car. Some well-known forms of flat engines tend to restrict lean and cornering in motorcycles. Flat engines lend themselves well to aircraft engines, where any extra building expense is of minor importance.
The flat configuration lends itself very well to air cooling designs such as the flat-4 in the VW Beetle, Porsche 356 and 912. The Chevrolet Corvair used an air-cooled flat-6, though this is something of a rarity in American designs. Both the older and newer models of the Porsche 911 use a flat-6, at first air-cooled but since the introduction of the Porsche 996 models are water-cooled. These automobiles situate the engine in the rear rather than the front, where its width does not interfere with the steering of the front wheels and to reduce weight by eliminating a front engine that requires a drive train.
Front-mounted air-cooled flat-twin engines were used by Citroën in their model 2CV and its derivatives, while the GS, GSA, Oltcit used a flat-four, and a flat-six was proposed for the DS, but rejected. BMW used an air-cooled flat-twin in almost all of its motorcycles from 1921 until 1980, and still depends heavily on this layout, using it in many models including its most popular bike, the R1200GS
All versions of the Subaru Impreza, Forester, Tribeca, Legacy, Outback and SVX use either a flat-4 or flat-6 engine.
"Boxers" can be subdivided, since true boxers have each crankpin controlling only one piston/cylinder, and 180° engines share crankpins.
Boxer engines must not be confused with opposed piston engines, which are based on a quite different concept using two crankshafts. These can be used in vehicles such as tanks.
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Boxer engines got their name because each pair of pistons moves simultaneously in and out rather than alternately, like boxers showing they're ready by clashing their gloved fists against each other before a fight. Boxer engines of up to eight cylinders have proved highly successful in automobiles and up to six cylinders in motorcycles, and continue to be popular for light aircraft engines.
Boxers are one of only three cylinder layouts that have a natural dynamic balance; the others being the straight-6 and the V12. These engines can run very smoothly and free of unbalanced forces with a four-stroke cycle and do not require a balance shaft or counterweights on the crankshaft to balance the weight of the reciprocating parts, which are required in other engine configurations. Note that this is generally true of boxer engines regardless of the number of cylinders (assumed to be even), but not true for all V or inline engines. However, in the case of boxer engines with fewer than six cylinders, unbalanced moments (a reciprocating torque also known as a "rocking couple") are unavoidable when the output is a crankshaft due to the "opposite" cylinders being not exactly opposite but offset slightly.
Boxer engines (and flat engines in general) tend to be noisier than other common engines for both intrinsic and other reasons, eg in cars, valve clatter from under the bonnet is not damped by large air-filters and other components. Boxers need no balance weights on the crankshaft, which should be lighter and fast-accelerating - but in practice (e.g. in cars) they need a flywheel to run smoothly at low speeds and this negates the advantage. They have a characteristic smoothness throughout the rev range and offer a low center of gravity. When combined with a mounting position immediately ahead of the rear axle (e.g. Porsche Boxster and Cayman but not Porsche 911 nor Volkswagen Beetle) they have largely neutral handling.
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