Ford's Chocolate Inspired Weight-Saving Technology

There are many areas where weight can be saved by changing the type or grade of metal used to a stronger, lighter material to trim kilos from the kerb weight. Plastic parts are an area where it is traditionally difficult to save weight without sacrificing strength, durability or function, but Ford has found a solution. MuCell technology introduces gas bubbles into the plastic as it is moulded, leaving a microscopic honeycomb structure. These tiny spaces save weight by reducing the amount of plastic used, without compromising the integrity of the part.

Weight plays a key role in vehicle emissions and reducing the overall mass of the vehicle results in improvements to fuel economy and carbon emissions. Vehicle weights have increased in the last 30 years to allow for much greater levels of equipment and radically improved safety attributes. Ford has targeted reducing weight while still providing class leading levels of equipment and 5-star Euro NCAP safety ratings.

MuCell brings a host of other benefits with lower pressures used to mould the plastic and up to 33 per cent more parts per hour than a conventional process. This increase in speed and efficiency reduces energy consumption, manufacturing emissions and cost for parts produced using the innovative technique.

MuCell technology expert Carsten Starke is excited by the potential of the new process. He says: "The first time I saw this plastic under the microscope I thought to myself it looks like an Aero chocolate bar! The bubbles in the chocolate change the taste, but in our plastics they save weight and making cars lighter reduces emissions and fuel consumption significantly.

"We are saving weight in many ways, not just by using this new plastic, because lighter cars handle better, accelerate faster and stop more quickly. For the customer it is win-win, the plastic is 20 per cent lighter without increasing cost or reducing strength and it will help make their Ford better in almost every aspect."

The MuCell technology will see its first application in engine covers which will be rolled out over the next few years on vehicles such as Focus, C-MAX and Grand C-MAX, S-MAX, Mondeo and Galaxy. Ford has committed to a minimum of 100kg weight reduction from even its smallest cars and 300kg from larger cars by 2020 as part of its environmental initiatives. This weight-saving initiative, which includes MuCell technology, also features a suite of other materials like high-strength Boron steels which are now used extensively in Ford models.