On February 17th, Ford Motor Company announced that its $5 billion "bet" on its next-generation all-electric vehicle will utilize an emerging technology that Tesla has already commercialized in its Cybertruck pickup truck in the United States.

This system, known as the 48-volt electrical architecture, has been discussed in the automotive industry for decades, but Tesla is the first company to bring it to consumers in 2023.

The automotive industry has historically used 12-volt systems and lead-acid batteries to power all vehicle accessories—a system riddled with problems and leading to numerous electric vehicle recalls. The new architecture, however, uses the electric vehicle's own high-voltage battery to power all components.

Ford states that the 48-volt system improves efficiency, increases power bandwidth, and reduces weight by reducing wiring. Furthermore, the voltage can be "stepped down" to 12 volts when necessary using new electronic control units (ECUs) that control different parts of the electric vehicle's architecture.

Ford believes this new electrical system is one of many innovations that will enable its next generation of electric vehicles—starting with a small, $30,000 electric pickup truck launching in 2027—to compete with Tesla and rapidly expanding Chinese brands in the global market.

"At Ford, we've taken on challenges that many other companies have given up on. We're challenging our competitors, including Chinese companies," Ford CEO Jim Farley said at an event in August at a Kentucky plant where the unnamed electric pickup truck will soon be produced. “Traditional automakers have been too conservative for too long.”

Farley called it the company’s “Model T moment,” referring to the flagship model launched over a century ago that spearheaded the mass adoption of automobiles in the early 20th century. He also called it a “high-stakes gamble” for Ford, given the numerous changes it will make to electric vehicles, the company, and its processes.

Ford expects its new electric vehicles, based on GM’s UEV platform, to achieve costs comparable to gasoline-powered cars through new technologies and efficiency improvements. Currently, the large batteries required for electric vehicles significantly increase production costs and have resulted in poor profitability.

The Detroit automaker says the new electric vehicles will have 20% fewer parts, 25% fewer fasteners, 40% fewer dock-to-dock bays, and 15% faster assembly compared to conventional cars.

“This represents the most radical change in how Ford designs and manufactures since the Model T,” Farley said at the plant. “It’s time to change the game again.”

Ford says these improvements, along with a price point closer to gasoline-powered models, will drive the adoption of electric vehicles. Despite a significant slowdown in U.S. electric vehicle sales due to the Trump administration's adjustments to federal support policies and lower-than-expected consumer acceptance,

According to data from Cox Automotive, U.S. electric vehicle sales peaked in September, accounting for 10.3% of the new car market, just before the end of federal subsidies. However, by the fourth quarter, this demand had plummeted to an estimated 5.8%.

Recently, due to unfavorable market conditions, Ford announced a $19.5 billion write-down, primarily related to the scaling back of its electric vehicle plans. However, the company stated that it will continue to invest $5 billion in its new UEV platform by 2027.

Alan Clark, Ford's executive director of advanced electric vehicle development, stated at a media briefing, "Our focus is on giving them everything a good car can offer, and more. We believe this will ultimately enable us not only to build an affordable car, but also a highly attractive one."

48-Volt System

Former Tesla executive Clark stated that the 48-volt system, in addition to providing significant advantages for the battery, also offers significant advantages for other parts of the vehicle, and is expected to continue to play this role as the bandwidth of 12-volt batteries reaches its limit. “It’s cheaper, has a finer wire gauge, and represents the future of the automotive industry,” he said. “So if you want this platform to last for more than a decade… it’s clear that 48-volt wire is the most logical choice.”

Ford says the wiring harness for its new mid-size truck will be more than 4,000 feet shorter and 22 pounds lighter than the harness used in Ford’s first-generation electric SUV.

Tesla CEO Elon Musk sent a “dosing guide” to competitors like Ford and GM on how to develop a 48-volt system by 2023.

Clark said Ford had already decided to adopt the 48-volt platform before receiving the letter, but the letter “undoubtedly added fuel to the fire” and “helped us understand their thinking.” He added that it also helps suppliers prepare to support the 48-volt system.

Gigafactory

In addition to the 48-volt system, the company also released more details on February 17 about how it will improve vehicle efficiency through aerodynamics, team “rewards,” and the adoption of Tesla’s pioneering “HyperBroadcast” technology to achieve its goals for its new electric vehicle.

Gigabit casting is a manufacturing process that replaces dozens of traditional small stamped parts with larger components. This process requires large machines to press large sheets of metal into shapes such as the front fascia or internal structure of a vehicle.

Ford says the new pickup truck has only two structural components, front and rear, while the current gasoline-powered Maverick mini-pickup has 146 such components.

Ford also says that the aluminum castings used in its upcoming electric vehicle are more than 27% lighter than similar components in the Tesla Model Y.

Clark said, “The cost of electric vehicles is still falling dramatically, and this can only be achieved through innovation and system-level optimization to ultimately create the products customers want.”