Ford to use MIT-developed MuCell plastics filled with air bubbles for weight reduction

Ford has started using an MIT-developed plastic technology called MuCell which injects tiny bubbles of gas into plastic during the manufacturing process to reduce its weight by 10% to 20% while keeping the same strength.

Naturally, the plastics also use less raw materials since it has swapped some plastic for bubbles of gas. The image above shows the internal structure of the MuCell plastic, which Ford likens to how an Aero chocolate bar looks like on the inside.

The first cars using MuCell plastics will roll out of the factory in the next few years. The first part to use MuCell is the engine cover. Ford did not reveal what else could be made out of MuCell plastics. But a little Googling has returned a Trexel Inc webpage with various examples like fan shrouds, radiator end tanks, wing mirror housings, door handles, airbag covers, and etc.

Mazda will also start using MuCell-produced parts for its instrument panel retainers and door panel liners.

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