Ford is preparing a major push into affordable electric vehicles with a new compact pickup priced around $30,000, and it’s using advanced engineering techniques inspired by Tesla and Formula 1 to make it happen.
The upcoming truck, expected to launch in 2027, will be the first Ford vehicle to use gigacasting, a manufacturing process pioneered by Tesla. Instead of assembling a vehicle from dozens or even hundreds of smaller parts, gigacasting uses massive presses to create large sections of the vehicle’s structure from single aluminum castings. Ford says this approach will dramatically simplify construction, reducing the number of structural parts in key areas from more than 140 pieces down to just two, according to Road and Track.
This shift offers several advantages. Fewer parts mean faster assembly, lower production costs, and reduced vehicle weight. According to Ford’s engineers, the new platform could be around 27 percent lighter than some of the most efficient electric vehicles currently available. That weight reduction directly improves efficiency, allowing the truck to deliver better range without needing larger and more expensive battery packs.
Ford’s engineering team has also drawn inspiration from Formula 1 racing to maximize efficiency through aerodynamic design. The truck will feature a teardrop-shaped roofline that creates a virtual aerodynamic surface over the open cargo bed, reducing drag. Engineers have redesigned side mirrors to improve airflow, while a smooth underbody panel helps air move more efficiently beneath the vehicle. These incremental aerodynamic improvements add up to meaningful gains in efficiency and performance.
Inside the vehicle, Ford is rethinking electrical architecture to reduce complexity and weight. The truck will use a modern 48-volt electrical system instead of the traditional 12-volt setup. This allows engineers to significantly reduce wiring, eliminating roughly 4,000 feet of cables compared to earlier Ford electric vehicles. The change alone saves about 22 pounds and simplifies the vehicle’s electronics.
Ford’s strategy reflects its effort to compete directly in the affordable EV market, which has become increasingly important as high EV prices remain a major barrier for mass adoption. By combining cost-saving manufacturing methods, advanced aerodynamics, and lightweight design, Ford aims to deliver a practical electric pickup with strong performance and range at a price point far lower than most current EV trucks.
The project also highlights how traditional automakers are increasingly adopting techniques pioneered by Tesla and motorsports engineering to remain competitive. If successful, Ford’s compact electric pickup could play a major role in making electric trucks accessible to a much wider audience.
