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Ford using plastics, composites and aluminum to lighten up the Fusion

By: AUTOMOTIVE NEWS

June 11, 2014

Ford’s Lightweight Concept shown last week cuts the weight of a 2013 Fusion mid-sized sedan nearly 25 percent, or about 900 pounds, by making maximum use of lightweight materials, the automaker says.

Among the changes: carbon-fiber reinforced plastic for seats, instrument panel, wheels and oil pan, and aluminum for sheet metal, brake rotors and front subframe.

Matt Zaluzec, Ford technical leader for global materials and manufacturing research, said that “lightweighting does not come for free.” But he said Ford is working to offset costs by combining parts and new manufacturing techniques.