As light as Aero

Ford has produced lighter plastics, as part of their quest to reduce weight and emissions inspired by the Aero chocolate bar. There are many ways to reduce weight when it comes to metals, such as changing the type or grade which can help shed kilos from the total weight.

Plastics have been a difficult area to reduce weight without sacrificing strength durability or function but the new MuCell technology works by introducing gas bubbles into the plastic as it is moulded, leaving a microscopic honeycomb structure. Having these tiny spaces save weight by reducing the amount of plastic need without compromising the integrity of the part.

The MuCell technology will be used in engine covers on vehicles such as the new Ford Mondeo in Livingston, Ford Focus, Galaxy, S-MAX, C-MAX and Grand C-MAX over the next few years. Ford has committed to a minimum of 100kg weight reduction from small cars and 300kg from large cars by 2020 as part of environmental initiatives.

Plastics have been a difficult area to reduce weight without sacrificing strength durability or function but the new MuCell technology works by introducing gas bubbles into the plastic as it is moulded, leaving a microscopic honeycomb structure. Having these tiny spaces save weight by reducing the amount of plastic need without compromising the integrity of the part.

Ford's MuCell technology expert Carsten Starke, said: "The first time I saw this plastic under the microscope I thought to myself it looks like an Aero chocolate bar! The bubbles in the chocolate change the taste, but in our plastics they save weight and making cars lighter reduces emissions and fuel consumption significantly, we are saving weight in many ways, not just by using this new plastic, because lighter cars handle better, accelerate faster and stop more quickly. For the customer it is win-win, the plastic is 20 per cent lighter without increasing cost or reducing strength and it will help make their Ford better in almost every aspect."we are saving weight in many ways, not just by using this new plastic, because lighter cars handle better, accelerate faster and stop more quickly. For the customer it is win-win, the plastic is 20 per cent lighter without increasing cost or reducing strength and it will help make their Ford better in almost every aspect."