Blue Oval claims its new EV architecture and total rethink of the production line process give it an advantage other automakers wont be able to copy
by Chris Chilton
15 hours ago
- Ford says its new generation of EVs will shake up the industry like the Model T did.
- It simplified its EV platform to reduce weight and costs, and reimagined the build line.
- Instead of traveling down one line, cars are built in three parallel lines that then merge.
The big news from Ford the past week was the announcement of the $30k electric pickup arriving in 2027, an EV that’s just the first of many coming in the next five years. But its engineers say the really big story is how they ripped up the rulebook on building EVs to come up with a production process that will leave rivals, and especially newcomers in the industry, floundering in its wake.
“I don’t think many legacy car manufacturers could pull off a project like this,” said Doug Field, Ford’s Chief EV, Digital and Design Officer. “And I don’t believe new electric vehicle startups will be able to keep up with our Ford engineers and manufacturing teams making this a reality.”
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Ford’s Universal Electric Vehicle Platform was conceived by a small skunkworks team headed by former Tesla engineer Alan Clarke, who worked in near secrecy in California with a bunch of brains recruited from inside and outside of the automaker’s ranks.
The architecture the team created broke from Ford tradition in key ways. One is the use of unicasting, where large one-piece aluminum castings replace multiple welded panels on a current Ford vehicle. This technology – also being used or developed by other brands, including Tesla and Toyota – allowed the team to eliminate three-quarters of the parts, two-thirds of the welds, and half of the fasteners versus a traditional pickup. Another big leap that saves both time and weight is the removal of almost a mile (1.6 km) of wiring versus an older of Blue Oval’s EV.
Ford
But equally important is how these new-generation EVs will be produced inside Ford plants. Henry Ford is credited with revolutionizing the car industry by introducing a moving production line that ramped up efficiency and drove down cost. Now, though, the company is moving away from the idea of a single production line to what it calls a production tree.
Instead of vehicles moving down one track, they’ll start off on three parallel lines, one building the front, one the rear and the other the structural battery core. When each sub-section is complete the three lines converge and the EV is finished off, having spent far less time in build than a conventional car. Ford says these combined efficiencies – the platform and the production process – will help it compete with Chinese automakers.
“The Model T was affordable not because it was a thrifted version of other cars, but because brilliant minds took fundamentally new approaches to old problems,” said Doug Field. “That’s exactly what we set out to do in creating the Ford Universal Electric Vehicle Platform.”
Ford says the 2027 mid-size electric truck will be as quick as an Ecoboost Mustang and as roomy as a Toyota RAV4. It also promised a five-year cost of ownership that will be “lower than buying a three-year-old Tesla Model Y.” Images shown at the pickup’s announcement revealed the same platform could be used to create a diverse range of other vehicles from a two-door panel van to a three row SUV.
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