Ford Battles Physics to Create Affordable Electric Vehicles
Ford is undergoing a significant shift in its approach to electric vehicles (EVs). After facing substantial financial losses, the company is pivoting towards more affordable and efficient EVs. This decision comes after Ford incurred a staggering $19.5 billion loss in its EV investments by 2025, impacting the iconic automaker’s profitability.
Ford’s New Direction in EV Development
In light of its challenges with the F-150 Lightning, Ford is emphasizing hybrids, extended-range EVs, and traditional vehicles, which continue to be profitable. Despite these obstacles, Ford remains committed to an electric future. The new strategy aims to create affordable electric vehicles that are engaging to drive.
The Universal EV Platform
Leading this initiative is Alan Clarke, Ford’s executive director for EV programs. Clarke manages a team of around 500 engineers dedicated to developing the Universal EV Platform (UEV). This platform will support a range of low-cost vehicles, starting with a $30,000 midsize truck expected to launch in 2027.
- Focus Areas: Efficiency, affordability, and innovation.
- Team Locations: Silicon Valley and Los Angeles.
Ford’s approach integrates advanced engineering with the scale of the company’s manufacturing capabilities, moving beyond initial design phases into preparations for mass production.
Addressing Battery Costs
A major challenge in reducing EV costs is the battery, which accounts for about 40% of the total vehicle price. Instead of waiting for breakthroughs in battery technology, Clarke’s team is optimizing range with smaller battery packs. They introduced a “bounties” system to assess efficiency in different design elements.
- Example: A one-millimeter change in roof height can reduce battery costs by $1.30.
- Material Evaluations: Light materials like smaller mirrors contribute to drag reduction and overall vehicle cost efficiency.
Streamlined Design and Engineering Innovations
Ford’s strategy includes significant redesigns of vehicle components to improve aerodynamics. Engineers collaborated with Formula One experts to optimize every detail. Strategies include adjusting the underbody structure and rethinking traditional components to enhance performance and efficiency.
For instance, the new side mirrors will be up to 20% smaller, resulting in less drag and adding about 1.5 miles of range.
Next-Generation Architecture
The UEV Platform departs from traditional vehicle architectures, adopting a zonal wiring system. This design reduces the number of electronic control units, streamlining processes and lowering production costs.
- E-Box Development: Incorporates multiple functions into a single module, enhancing serviceability and power management.
Looking Ahead
While Ford faces external challenges, including market political hurdles, the company is focused on in-house innovation. The UEV project aims to bring more systems under Ford’s direct control, reducing reliance on third-party suppliers for future developments.
Ford plans to unveil designs for its future EVs, which will prioritize aerodynamic efficiency without compromising truck utility. These developments mark a bold new chapter in Ford’s long history as it aims to redefine its role in the evolving automotive landscape.
