Ford has announced its ambitious plan to introduce an electric truck next year, with a starting price of $30,000, aimed at competing effectively against Chinese manufacturers while maintaining profitability. This initiative will leverage a mix of 3D-printed components, insights from Formula 1, and an innovative bounty program to achieve its goals, as stated by the company on Tuesday.
Following a significant $19.5 billion setback in December and the cessation of its battery-electric F-150 Lightning production, Ford is determined to ensure that its new electric vehicle (EV) strategy succeeds.
The company began its journey toward affordable EVs several years ago, spearheaded by a specialized team led by Alan Clarke, a former Tesla executive. Last August, Ford revealed plans to replace its traditional assembly line with a new system, investing $2 billion in its Louisville factory to enhance manufacturing efficiency by 15%.
Ford's upcoming EV lineup will be constructed on a universal platform featuring single-piece aluminum unicastings to streamline assembly and lithium iron phosphate batteries utilizing technology licensed from a Chinese partner.
In a recent series of blog and social media updates, Ford detailed its strategy for delivering an appealing EV truck that is projected to be $20,000 less than the average new vehicle, while still ensuring profitability. Although specific details about range, features, and charging times were not disclosed, the company emphasized its commitment to producing lighter, more efficient EVs with fewer components.
The universal EV platform, or UEV, will initially support a mid-sized truck and may later accommodate a sedan, crossover, three-row SUV, and small commercial vans. This marks a significant shift for Ford, which previously adapted existing models for its Mustang Mach-E and Lightning EVs.
"This platform prioritizes efficiency and affordability, making long-range electric travel accessible to a broader audience," Clarke explained during a media briefing.
To realize these objectives, Clarke is fostering a culture enriched by talent from Formula 1 and tech giants like Apple, Lucid Motors, Rivian, and Tesla. The team, consisting of around 450 members in Long Beach, California, and 200 in Palo Alto, has also implemented a bounty program to help engineers understand the impact of their decisions on customer satisfaction and product quality.
The bounty program emphasizes efficiency, assigning numerical values to various aspects of the UEV, including weight, aerodynamic drag, and specific components. For instance, Ford may opt for a pricier part if it contributes to reducing the vehicle's weight, thereby enhancing efficiency and affordability.
"We are committed to ensuring that cost reductions do not compromise value," Clarke noted. Even the base model of the EV truck will include a power-folding mirror, a premium feature in many vehicles, as it reduces drag. The company achieved savings by utilizing a single motor for both mirror adjustments and folding.
Ford's focus on efficiency involved collaboration with former F1 engineers, resulting in a mid-sized EV truck that boasts a 15% improvement in aerodynamic efficiency compared to current market offerings.
The engineering team utilized 3D-printed and machined parts to construct a modular test vehicle, employing thousands of 3D-printed components that are highly precise and easily replaceable. These prototypes facilitated extensive wind tunnel testing early in the design phase, a departure from Ford's conventional practices.
Battery efficiency was a key focus, as it represents a significant portion of a vehicle's total cost. A lighter, more efficient design allows for a smaller battery, leading to cost reductions. Clarke anticipates that the resulting EV truck will offer approximately 15% greater range, translating to an additional 50 miles compared to a gasoline-powered equivalent.
Ford has also adopted manufacturing techniques popularized by Tesla, including aluminum unicastings and transitioning from a 12-volt to a 48-volt power system for various vehicle functions.
Moreover, Ford has restructured the UEV's electric architecture, adopting a zonal approach similar to that of Tesla and Rivian. This strategy consolidates multiple electronic control units (ECUs) into five main modules, simplifying design, reducing costs, and decreasing copper usage. This innovation has resulted in a wire harness that is 4,000 feet shorter and 22 pounds lighter than those in earlier electric vehicle models.
Additionally, Ford has developed proprietary software for these five main ECUs, enhancing portability and control over vehicle functions, from infotainment to body controls, allowing for a more integrated user experience.