Ford engineers drew on Formula 1 racing knowledge to refine the aerodynamics of its upcoming mid-size electric truck. More than half the team has racing backgrounds. This work delivers over 15 percent better efficiency than any current pickup truck. As a result, the design supports longer range and lower costs.
Highlights
- Achieves more than 15% superior aerodynamic efficiency versus any pickup truck
- Projects nearly 50 miles extra range with the same battery as top mid-size gas trucks
- Offers 30% efficiency gain at highway speeds
- Uses early wind tunnel testing with modular prototypes for rapid gains
F1-Inspired Process Accelerates Innovation
The aerodynamics team adopted a “fail fast, learn faster” mindset from motorsport. They moved wind tunnel work to the start of design instead of final validation. However, a modular “LEGO-like” test vehicle allowed swaps of 3D-printed parts in minutes.
Engineers tested thousands of components at 87 mph on a specialized treadmill. This data refined both physical results and simulation models. For example, real-time digital tools let teams in Michigan and California compare live results instantly.
Targeted Design Features Cut Drag
Designers addressed specific details to reduce resistance.
Virtual Surface Over Truck Bed
The roofline forms a teardrop shape that extends over the bed. This virtual surface lets air flow as if over a sleek closed body. Consequently, the truck behaves aerodynamically like a sedan rather than a traditional pickup.
Compact Mirrors Add Range
Engineers combined mirror adjustment and folding into one actuator. The housing shrank by over 20 percent. This lowers frontal area and mass, adding an estimated 1.5 miles of range.
Underbody Shields Manage Tire Wake
Flush bolts and smooth channels guide airflow around front tires toward rear ones. This approach hides rear wheels from high-speed flow. As a result, it adds about 4.5 miles of estimated range.
Range Gains Support Affordable EVs
Ford projects the new truck offers nearly 50 miles—or 15 percent—more range than one using the aerodynamics of the most efficient mid-size gas trucks. Highway speeds show a 30 percent improvement. These figures stem from internal testing and comparisons to models like the 2025 Ford Maverick.
Real-world track and street testing now follows. Insights will refine production and guide the Universal EV Platform. Overall, the system approach prioritizes efficiency for competitive electric pickups.
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