Ford Replaces 146 Parts with Two in Creating the Fathom Electric Pickup
Ford is implementing large-scale aluminum casting technology in the production of the new Fathom electric pickup.
Two single-piece castings for the front and rear sections of the body replace 146 individual structural components. Tesla previously began using a similar technology.
The company has already manufactured over 5,000 such castings at its facility in Shelbyville, U.S. These are used for testing the production process and assembling prototypes.
Production starts with melting aluminum at a temperature of about 700 °C and pouring the metal into special molds. The parts then undergo dimensional checks, X-ray inspection for internal defects, optical scanning, and laboratory strength tests.
At the assembly plant in Louisville, the front and rear sections of the pickup, as well as the battery section and interior components, will be assembled in parallel and joined at the final stage.
Ford plans to begin production of the Fathom in 2027. The stated starting price of the electric pickup is $28,350, excluding taxes and additional fees.
