An electric pickup as fast as the Mustang EcoBoost that costs only $30,000? That is what Ford promises will be first to come off the line of its new universal electric vehicle platform and production system.
Set to launch in 2027, the midsize, four-door electric pickup represents the debut of a new family of Ford EVs produced using the novel system, which takes its cue from the time-tested Ford manufacturing process while reconceptualizing the traditional assembly line.
The system represents a company investment of about $5 billion and will create or secure nearly 4,000 jobs.
“We took a radical approach to a very hard challenge: Create affordable vehicles that delight customers in every way that matters — design, innovation, flexibility, space, driving pleasure and cost of ownership — and do it with American workers,” said Jim Farley, president and CEO of Ford. “We have all lived through far too many ‘good college tries’ by Detroit automakers to make affordable vehicles that ends up with idled plants, layoffs and uncertainty, so this had to be a strong, sustainable and profitable business.
“From day one, we knew there was no incremental path to success. We empowered a tiny skunkworks team three time zones away from Detroit, we tore up the moving assembly line concept and designed a better one, and we found a path to be the first automaker to make prismatic LFP batteries in the U.S.”
The new platform reduces parts by 20 percent compared to a typical vehicle, requiring 25 percent fewer fasteners and 40 percent fewer workstations dock-to-dock while providing a 15 percent faster assembly time. For example, the wiring harness in the new midsize truck will be more than 4,000 feet shorter and 10 kilograms lighter than the one in Ford’s first-generation electric SUV.
Lithium iron phosphate prismatic batteries also foster space and weight savings while reducing costs and enhancing durability for customers. The platform’s cobalt-free and nickel-free LFP battery pack is a structural subassembly that also serves as the vehicle’s floor, providing a low center of gravity that improves handling while facilitating a quiet cabin and allowing for ample interior space.
Assembled at the Ford Louisville Assembly Plant in Kentucky for U.S. and export markets, the new truck is expected to provide more passenger room than the latest Toyota RAV4, not including the frunk and a truck bed that allows gear to be locked into place.
And yes, the truck will have a targeted 0-to-60 time as quick as the Mustang EcoBoost and with more downforce. With the low center of gravity, instant torque from the electric motors and a well-engineered chassis are geared toward making the truck as fun to drive as it is practical.
“We took inspiration from the Model T — the universal car that changed the world,” said Doug Field, Ford’s chief EV, digital and design officer. “We assembled a really brilliant collection of minds across Ford and unleashed them to find new solutions to old problems. We applied first-principles engineering, pushing to the limits of physics to make it fun to drive and compete on affordability. Our new zonal electric architecture unlocks capabilities the industry has never seen.
“This isn’t a stripped-down, old-school vehicle.”
The new EV production system transforms the traditional assembly line into an “assembly tree.” Instead of relying on one long conveyor, three subassemblies run down their own lines simultaneously and then join together.
The front and rear of the vehicle will be assembled separately thanks to large, single-piece aluminium unicastings that replace dozens of smaller parts traditionally used in production. The structural battery is also an independent subassembly that includes seats, consoles and carpeting.
Parts travel down the assembly line in a kit, within which all fasteners, scanners and power tools required for the job are included in the correct orientation for use. The system dramatically improves ergonomics for employees by reducing twisting, reaching and bending.
“We put our employees at the center and recreated the factory from scratch,” said Bryce Currie, vice president of Americas Manufacturing. “We live and breathe continuous improvement, but sometimes you need a dramatic leap forward. We expect ergonomic breakthroughs and complexity reduction through elimination of parts, connectors and wire will flow through to significant quality and cost wins.”
The assembly time for the new truck could be as much as 40 percent faster than that of the plant’s current vehicles, time Ford plans to reinvest into insourcing and automation to improve quality and cost, ultimately netting a 15 percent speed improvement.
Ford plans to invest nearly $2 billion into the Louisville plant to assemble the midsize electric truck, securing nearly 2,200 hourly jobs. The project is supported by an incentive offer from the Kentucky Economic Development Finance Authority.
“This announcement not only represents one of the largest investments on record in our state; it also boosts Kentucky’s position at the center of EV-related innovation and solidifies Louisville Assembly Plant as an important part of Ford’s future,” Kentucky Gov. Andy Beshear said. “Thanks to Ford’s leaders for their continued faith in Kentucky and our incredible workforce.”
The plant will expand by 52,000 square feet to move material more efficiently. Digital infrastructure upgrades will provide the plant with the fastest network with the most access points of any Ford plant globally, enabling more quality scans.
The investment in the Louisville plant is in addition to Ford’s previously announced $3 billion investment in BlueOval Battery Park Michigan, which will build the prismatic LFP batteries for the midsize electric truck starting next year.
Ford plans to invest about $5 billion and create or secure nearly 4,000 direct jobs between the two plants while strengthening the domestic supply chain by enlisting dozens of new, U.S.-based suppliers.
READ ALSO: Growth Brings Big Names: Little Rock Touchdown Club Gears Up for 2025 Season
