Fender Bender: Chocolate inspiration for weight loss

Ford engineers have taken inspiration from the Aero chocolate bar to produce stronger, lighter material which will trim kilos of curb weight off. Saving weight on plastic parts without affecting performance is tricky, so Ford’s solution is MuCell technology which introduces gas bubbles into the plastic as it is moulded, leaving a microscopic honeycomb structure.

“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,” Ford’s MuCell technology expert, Carsten Starke, said. “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.”
 
Benefits include
Honeycomb structure – MuCell plastic parts save 20 per cent weight, improving fuel economy and emissions, without compromising durability

• Injection of gas during moulding creates a cross-section resembling an Aero chocolate bar on a microscopic level, with the bubbles meaning less plastic is used

• Parts require less energy and time to manufacture, reducing emissions and cost.