Ford’s Electric Future: Borrowing from Tesla to Drive Down Costs
Ford is making a significant $5 billion investment in its next generation of electric vehicles, and a key component of that strategy involves adopting a technology first popularized by Tesla: the 48-volt electrical architecture. This move, announced Tuesday, signals a shift in the automotive industry as manufacturers seek to lower EV production costs and increase efficiency.
The 48-Volt Revolution
Traditionally, vehicles have relied on a 12-volt system powered by lead-acid batteries. However, this system has proven problematic, leading to recalls in many electric vehicles. Ford’s adoption of a 48-volt system, initially commercialized by Tesla in the Cybertruck in 2023, utilizes the EV’s high-voltage battery to power all vehicle functions. This approach improves efficiency, increases electrical bandwidth, and reduces weight by minimizing the amount of wiring needed.
Alan Clarke, Ford’s executive director of advanced EV development, emphasized the benefits, stating it’s “less expensive, has smaller wires and is the future of automotive.” He also noted that Ford had already decided on a 48-volt platform before receiving a “helpful starting point” from Tesla, which also aided suppliers in preparing for the new system.
Gigacastings and Streamlined Manufacturing
Beyond the electrical architecture, Ford is also embracing Tesla-pioneered “gigacastings” to simplify manufacturing. This process replaces numerous modest, stamped parts with larger, cast components. Ford’s new midsize pickup will utilize only two structural front and rear parts, compared to the 146 components found in its current gas-powered Maverick. These aluminum castings are also reportedly more than 27% lighter than those used in a Tesla Model Y.
A $30,000 Electric Pickup on the Horizon
Ford plans to launch its next-generation EVs with a small electric pickup truck priced around $30,000 in 2027. This is a crucial step towards making EVs more accessible to mainstream buyers. The company aims to reduce parts count by 20%, fasteners by 25%, workstation needs by 40%, and assembly time by 15% with these new technologies.
Ford CEO Jim Farley has described this initiative as a “Model T moment” for the company, referencing the historical impact of Ford’s first mass-produced vehicle. He also acknowledged the challenges, calling it a “bet” for Ford given the extensive changes required.
Facing Market Realities
Despite the ambitious plans, Ford recently announced $19.5 billion in write-downs related to a pullback in EV plans, citing a slowdown in U.S. EV sales. However, the company remains committed to investing $5 billion in its Universal Electric Vehicle (UEV) platform through 2027.
The Future of EV Architecture
The shift towards 48-volt systems and gigacastings represents a significant evolution in EV manufacturing. These innovations not only promise to lower costs but also improve vehicle performance and efficiency. As the EV market matures, expect to observe more automakers adopting these technologies to remain competitive.
Pro Tip:
The 48-volt system isn’t just about cost savings. It also provides greater bandwidth for future technologies, ensuring vehicles can accommodate increasingly complex electrical systems.
FAQ
Q: What is a 48-volt electrical architecture?
A: It’s a new system that uses the EV’s main battery to power all vehicle functions, improving efficiency and reducing wiring complexity.
Q: What are gigacastings?
A: Gigacastings are a manufacturing process that replaces many small parts with fewer, larger cast components, simplifying assembly and reducing weight.
Q: When will Ford release its $30,000 electric pickup?
A: Ford plans to launch the truck in 2027.
Q: Did Ford copy Tesla?
A: Ford is adopting a technology Tesla pioneered, but also states they were already planning to implement a 48-volt system before Tesla shared their insights.
Q: What is the Universal Electric Vehicle (UEV) platform?
A: It’s Ford’s new dedicated EV platform designed to be the foundation for a range of future electric vehicles.
Did you know? Tesla sent competitors a “how-to” guide on developing a 48-volt system in 2023.
Want to learn more about the future of electric vehicles? Explore our other articles on EV technology and market trends.
