Ford is applying Formula 1-inspired engineering and development methodologies to shape its next-generation mid-size electric truck, aiming to significantly improve aerodynamic efficiency, driving range, and overall customer value, the company said in a recent technical update.
Ford’s advanced aerodynamics team, with more than half of its members coming from Formula 1 backgrounds, has achieved over 15% better aerodynamic efficiency than any current pickup truck on the market, a breakthrough expected to translate into longer driving range and lower battery costs.
F1-Inspired Development Approach
To accelerate innovation, Ford adopted a “fail fast, learn faster” development philosophy commonly used in Formula 1. Unlike traditional automotive processes where wind tunnel testing is conducted late in the design cycle, Ford integrated wind tunnel testing from the earliest stages of vehicle design. Engineers used modular, rapidly swappable 3D-printed components to test thousands of aerodynamic configurations in minutes, enabling rapid iteration and data-driven decision-making.
The company also rebuilt its digital aerodynamic toolkit, creating real-time data pipelines and visualization systems that allowed engineers across locations to collaborate seamlessly. These tools are expected to serve as a foundation for future AI-driven vehicle design.
Key Aerodynamic Innovations
Ford engineers focused on three major aerodynamic advancements to extend the electric truck’s range:
- Virtual Surface Roofline: A teardrop-shaped roofline directs airflow over the truck bed, reducing drag and improving efficiency.
- Compact Mirror Design: A redesigned mirror housing reduced frontal area by over 20%, adding an estimated 1.5 miles of range.
- Optimized Underbody Design: A racing-inspired flat underbody and managed tire airflow contributed an additional 4.5 miles of range.
Up to 50 Miles More Range
Ford estimates that its new electric truck could deliver nearly 50 miles or about 15% more driving range compared to similarly sized gas-powered trucks with equivalent battery capacity, with up to 30% efficiency improvement at highway speeds.
The company is now moving into real-world testing on tracks and urban roads to validate its aerodynamic gains and refine production models. These innovations will form a core part of Ford’s upcoming Universal EV Platform, which aims to reduce battery size while maximizing performance and affordability.
Ford said its systems engineering approach integrates design, software, manufacturing, and supply chain decisions to optimize electric vehicle development, underscoring its push to deliver next-generation electric trucks with improved efficiency and cost-effectiveness.
