Ford is demonstrating its ability to build lightweight vehicles with a 2013 Fusion prototype that is 700 lbs (317.5 kg) lighter than the production car thanks to the use of high-strength steel and aluminum alloys. To achieve this result, Ford has used materials and technologies similar to those on the all-new F-150 pickup truck.

The 25 percent weight reduction makes the 2013 Fusion as light as a Ford Fiesta, resulting in better performance, gas mileage and carbon dioxide emission reduction. Ford says these lightweight technologies can be produced in large volumes across the product lineup.

“Consumers today want better fuel efficiency, but they also want more technology and features in the car, which usually adds weight to the vehicle,” said Raj Nair, Ford group vice president, Global Product Development. “A focus on light-weighting will be fundamental to our industry for years to come, and we are investigating many advanced materials applications as possible solutions for weight reduction in our vehicles,” he added.

Ford’s Lightweight Concept uses many of the same advanced materials found in today’s electronic devices, including aluminum, chemically toughened glass and advanced lightweight plastics. These materials were incorporated into the entire design of the vehicle, including powertrain, chassis, body, battery and interior features such as seats.

Developed with the U.S. Department of Energy’s Vehicle Technologies Program, together with Cosma International, the research vehicle points the way for lightweight technologies of the future.

By Dan Mihalascu

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