"Ford Executive States 'I Don't Think EV Startups Can Compete with Our Engineers' | Carscoops"

      Blue Oval asserts that its new EV architecture and a complete overhaul of the production line process give it a competitive edge that other automakers will struggle to replicate.

      Ford claims its upcoming generation of electric vehicles will transform the industry similarly to how the Model T did.

      The company has streamlined its EV platform to minimize weight and costs while rethinking the assembly line process.

      Rather than moving down a single line, vehicles will be manufactured on three parallel lines that later merge.

      Recently, Ford announced a $30,000 electric pickup scheduled for release in 2027, which is just the first of many models set to debut over the next five years. However, engineers emphasize that the true innovation lies in their reimagined approach to EV manufacturing, which could leave competitors, particularly new entrants, struggling to keep pace.

      “I don’t believe many established automakers could successfully execute a project like this,” stated Doug Field, Ford’s Chief EV, Digital and Design Officer. “I also doubt that new electric vehicle startups can match the capabilities of our Ford engineers and manufacturing teams in bringing this to fruition.”

      Ford’s Universal Electric Vehicle Platform was developed by a small team led by former Tesla engineer Alan Clarke, operating in relative secrecy in California, comprised of talented individuals sourced from both within and outside the company.

      The architecture developed by this team deviates significantly from Ford's traditional methods. One key change is the adoption of unicasting, where large, single-piece aluminum castings replace multiple welded panels found in current Ford vehicles. This technology, which other brands such as Tesla and Toyota are also implementing, allowed the team to reduce the total number of parts by three-quarters, welds by two-thirds, and fasteners by half compared to a conventional pickup. Another major advancement is the reduction of nearly a mile (1.6 km) of wiring compared to Ford's previous EV models.

      Equally critical is how these new EVs will be assembled within Ford factories. Henry Ford is renowned for revolutionizing the automotive industry with the introduction of a moving production line that enhanced efficiency and lowered costs. Now, however, the company is shifting away from the concept of a single production line towards a so-called production tree.

      Instead of the vehicles following a single track, they will begin on three parallel lines, with one line focusing on the front, another on the rear, and the third on the structural battery core. Once each sub-section is complete, the three lines will converge, resulting in a finished EV that spends significantly less time in the assembly process compared to traditional vehicles. Ford believes these combined efficiencies—both in platform and production methods—will enable it to effectively compete with Chinese manufacturers.

      “The Model T was accessible not because it was a stripped-down version of other cars, but because ingenious minds adopted entirely new strategies to solve old challenges,” noted Doug Field. “That’s precisely the goal we aimed for in developing the Ford Universal Electric Vehicle Platform.”

      Ford anticipates that the mid-size electric truck launching in 2027 will be as fast as an Ecoboost Mustang and spacious as a Toyota RAV4. The company has also pledged that the total cost of ownership over five years will be “lower than purchasing a three-year-old Tesla Model Y.” Images released at the truck’s announcement indicated that this platform could support a broad array of vehicles, from a two-door panel van to a three-row SUV.