Ford: Lighter chassis, stronger performance
Spearheaded by Ford, the eShadow project represents an innovative approach to addressing the challenges of optimising vehicle weight and payload in electric commercial vehicles.
This project, match-funded by government and facilitated through the Advanced Propulsion Centre UK, was a collaboration between Ford, the University of Warwick, Gestamp, and Expert Technologies Group. The aim was to develop a lightweight chassis design that significantly improves payload capacity without compromising durability or cost-effectiveness.
In transitioning commercial fleets to electric power, one of the primary challenges is the weight of the batteries reduces the available payload capacity. The eShadow project sought to mitigate this issue by developing a ladder chassis that is 40% lighter than conventional designs. This was achieved by using advanced carbon-fibre composites for major chassis elements, with strategically placed steel and aluminum components used where necessary to enhance performance while minimising weight.
By reducing the chassis weight, Ford’s goal was to maximise payload capacity and provide a sustainable, efficient solution for electric commercial vehicles. The weight savings achieved also enable significant fuel savings for vehicles powered by more conventional powertrains.
To streamline the process, Gestamp developed an advanced computer model incorporating the novel composite materials and joining methods, that minimised design iterations, and optimised for weight, cost, sustainability, and ease of manufacture. Virtual validation was also key, enabling the consortium to assess design variations digitally and refine the assembly process, ensuring efficient production and consistent quality.
To prove the durability of the eShadow chassis design, six prototype vehicles were built and underwent rigorous durability testing at Gestamp’s UK facility and Ford’s proving ground at Lommel, confirming the chassis’ suitability for real-world applications. Funded by the Department for Business and Trade and delivered through the Advanced Propulsion Centre UK, eShadow showcases the potential for collaborative innovation in positioning the UK as a leader in sustainable vehicle technology. This project not only meets the needs of the electric commercial vehicle sector but also sets the stage for future advancements in lightweight, composite-based automotive design.
eShadow was an £8.5 million project which received £4.1 million in government grant funding through the Advanced Propulsion Centre UK.
Watch the video above to learn more about this project and its impacts.
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