Ford is preparing to launch a $30,000 mid-size electric truck in 2027 that incorporates key technologies from Tesla's Cybertruck, including 48-volt architecture and gigacasting. The project is led by former Tesla executives and marks a significant shift for the automaker away from traditional methods. This approach aims to reduce costs and improve efficiency in electric vehicle production.
Ford's upcoming mid-size electric truck, set for release in 2027, starts at $30,000 and builds on innovations pioneered by Tesla for the Cybertruck. The vehicle utilizes a new Universal Electric Vehicle (UEV) platform developed by a team including Doug Field and Alan Clarke, both former Tesla executives with extensive experience in the company's engineering.
A major change is the adoption of a 48-volt electrical system, moving away from the industry's standard 12-volt setup. This follows Tesla's lead, where Elon Musk shared an open-source guide on the technology with other automakers in 2023. Ford CEO Jim Farley acknowledged receipt of the document, stating, "They weren't joking. We received the document today, dated Dec. 5th. Thanks, @ElonMusk. Great for the industry!" Combined with a zonal architecture, the system reduces wiring by over 4,000 feet and 22 pounds compared to the Mustang Mach-E.
Manufacturing efficiency is enhanced through "Unicasting," Ford's version of Tesla's gigacasting process. The front and rear structures, which require 146 stamped parts in the gas-powered Maverick, are consolidated into two large aluminum castings. The structural battery pack, using cost-effective LFP (lithium-iron phosphate) cells, serves as the vehicle's floor, helping achieve over 300 miles of range despite the batteries' lower energy density.
Assembly departs from the traditional moving line, employing an unboxed strategy with three independent sub-assemblies: front casting, rear casting, and battery core. This method improves worker ergonomics, cuts build time by 15 percent, and reduces workstations by 40 percent. By applying these Tesla-inspired techniques to an affordable truck, Ford seeks to broaden electric vehicle accessibility.
