Photo: MuCell plastic

Chocolate Bubble
Inspired Plastic

The engineering of bubbles at Ford

Even the smallest pattern can make the biggest difference. Inspired by the bubbles in the Aero chocolate bar, Ford was inspired to make cars with lighter, more environmentally friendly interiors.
Ford engineers knew that reducing the weight of materials would decrease energy consumption, yet doing so without sacrificing quality or performance proved a formidable problem. Yet by injecting gas bubbles into plastic, they developed an elegant solution they dubbed MuCell.
The outcome of the process is a microscopic honeycomb structure that saves weight by reducing the amount of plastic used without compromising the integrity of the part. The resulting increase in speed and efficiency reduces energy consumption, in turn helping the planet.
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