Ford targets lighter cars with carbonfibre subframe

Ford has teamed up with Canadian auto-supplier specialist Magna to develop a carbonfibre subframe for improving the fuel efficiency and dynamic ability of future vehicles.

The carbonfibre-reinforced composite subframe is claimed to reduce weight by more than a third compared with one constructed from stamped-steel.

Magna said the subframe reduces the number of parts required by 87 per cent – replacing 45 steel parts with just four metallic parts plus two moulded parts held together by adhesives and rivets.

The company says subframe prototypes are now being tested in vehicles after computer-aided engineering analysis pointed to successful chassis integration.

Magna says the testing phase will “evaluate corrosion, stone chipping and bolt load retention, which aren't currently measured by CAE”.

“We must continue to work hard to achieve these lightweight solutions at the most affordable costs,” said Mike Whitens, Ford Research and Advanced Engineering’s director of vehicle enterprise systems.

“Magna and Ford working together on this carbonfibre composite subframe is a great example of collaboration on advanced materials.”

Related statements from Ford and Magna speak exclusively to the efficiency advantages of bringing down vehicle mass, though removing front-end weight has inherent performance benefits such as reduced understeer and sharper cornering.

Subframes play a crucial role in a vehicle’s construction – commonly used for attaching the engine and wheels, and contributing to overall rigidity and crash resistance.

Carbonfibre was once considered prohibitively expensive for mainstream car makers but its use is becoming increasingly popular in an era of ever-tightening emissions regulations.

Magna and Ford previously collaborated on a carbonfibre grille opening reinforcement for the previous version of Blue Oval’s hotter Mustang, the Shelby Cobra GT500 (the latest GT350R model features carbon fibre wheels from Australian company Carbon Revolution).