Ford says it is completely rethinking how it engineers a vehicle with the development of its upcoming sub-$30,000 US electric pickup. The automaker is now outlining several key elements aimed at optimizing the product for efficiency, simplicity and cost.
- The electrical system will operate on 48V
- Aerodynamic optimization could add approximately 80 km of range
- Assembly techniques draw inspiration from Tesla’s manufacturing advances
According to Mike Colias in his book “InEVitable, Inside the Messy, Unstoppable Transition to Electric Vehicles,” Ford CEO Jim Farley was far from pleased at the launch of the Ford Mustang Mach-E. More specifically, when he discovered that the Mach-E weighed 70 pounds more than the Tesla Model Y, used 40% more fasteners and wiring harnesses, and was significantly less efficient in terms of energy consumption.
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Ford Electric 2.0
With Ford’s new “Electric 2.0” plan, everyone involved in the program is being asked to double down on improving overall vehicle efficiency. Engineers and designers alike are expected to work collectively to ensure that this new compact electric pickup meets its targets: greater efficiency, reduced complexity, lower energy consumption and, most importantly, a base price of around $30,000 US — roughly $40,000 to $41,000 CAD.
Reducing Weight
To achieve this, the vehicle’s very structure will borrow from Tesla’s approach with the Model Y. There will be the battery pack, along with just two other main sections — one at the front and one at the rear — that will join at a precise point to simplify the assembly process. By limiting the vehicle to two primary structural sections, Ford significantly reduces the number and complexity of components compared to the Maverick, which uses 146 structural parts. For the company that pioneered the automotive assembly line, this represents a major shift.
Reducing everything is also critical. For example, larger components will now replace what was previously an amalgamation of smaller pieces. Ford claims it will eliminate the equivalent of 1.2 kilometres of wiring — roughly 22 pounds of mass — compared to the Mach-E.
Ford future EV compact pick-upElectronic components are also a major contributor to vehicle weight. BMW has positioned itself as a pioneer in this area with its Neue Klasse platform, which relies on just four computers rather than the several dozen typically found in a “traditional” vehicle.
Ford is moving in a similar direction, introducing only five control units known as “Energy Management Unit box” to oversee full vehicle management. This marks a significant reduction compared to the roughly 30 modules found in older-generation operating systems.
In the same vein, Ford is completely rethinking its electrical architecture with the adoption of a modern 48-volt system. With this approach, Ford maintains that charging efficiency and battery management will be considerably improved compared to its current systems.
More Advanced Aerodynamics
Talking about aerodynamics is often easier said than done — particularly in the case of a pickup truck, where the bed configuration presents inherent challenges. With this new vehicle, Ford is focusing on fine details, such as side mirrors that are 20% smaller than those on the Maverick. According to Ford, this change alone could “add” 2.4 kilometres of range.
Ford future EV compact pick-upUnderneath the vehicle, airflow management is being studied extensively. Engineers aim to redirect air around the wheel wells, potentially recovering just over seven kilometres of additional range. Perhaps the most surprising design element will be the extension of the cab flowing into the bed area, forming what is described as a teardrop configuration. The final result remains to be seen, but Ford says it has brought in aerodynamic specialists directly from motorsport — specifically Formula 1.
Based on Ford’s projections, intensive bodywork refinements alone could yield approximately 80 kilometres of additional range. As a result, the company claims this will be the most aerodynamic pickup on the market. Saleem Merkt, the project’s head of aerodynamics, summarizes his team’s efforts: “You may not see the air we’ve managed, but you’ll certainly feel the difference on the drive.”
Democratizing Electrification
The ambitions behind this project are significant, as Ford is targeting large-scale democratization of electrification. Alan Clarke, executive director of advanced EV development, puts it plainly: “Our quest is ultimately to democratize electric vehicles.”
He adds, “The introduction of these bounties is a key element to how the team has been able to really tangibly show every engineer, every product designer, how they impact the customer and cost of the vehicle on a daily basis as they do their work.”
