It’s a good assumption thatlighter carsare generally better. Lightweights are faster, lighter on fuel and handle is better. Ford has proven how important weight reduction is with the Lightweight Concept vehicle.

Cleverly constructed from high-strength steel, carbon fibre, magnesium and aluminium, this concept has shown as much as 317 kg can be lost. The whole idea behind the Ford Lightweight Concept is to experiment with different weight-reduction methods and materials which will result in better performance and reduced fuel consumption across Ford’s product range.

“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.”

Every single aspect of the vehicle was examined for potential weight saving. The engine, the chassis,body, battery and interior features such as seats were inspected. The result is a big Ford Fusion sedan weighing the same as a standard Ford Fiesta.

Ford Lightweight Concept changes

• Suspension components, which led to a 30 percent weight reduction through the use of:

– Tall, narrow tires

– 19” by 5” carbon fibre wheels

– Aluminium brake rotors coated with steel

– Composite and hollow steel coil springs

– Lightweight hollow steel stabiliser bars

• Interior components, which led to a 35 percent weight reduction through the use of:

– Carbon fibre seats

– Carbon fibre interior components

– Foamed interior plastic trim, which saved 15 percent

• Lightweight glazing, which saved 35 percent:

– Polycarbonate rear window

– Hybrid chemically toughened laminate (chemically toughened glass plus soda lime glass) windshield and door glass

• Powertrain design, which led to a 24% weight reduction through the use of:

– 1.0-liter aluminium EcoBoost 3-cylinder engine

– Hollow steel crankshafts and forged aluminium connecting rods

– Carbon fibre oil pan, front cover and cam carrier

– Cast aluminium and magnesium transmission components

• Body- and door-in-white designs, which led to a 25 percent weight reduction through the use of:

– Aluminium sheet

– Aluminium extrusions

– Aluminium castings

– Advanced High Strength Steel

– Ultra High Strength Steel

– Magnesium (small casting in front doors)