Ford uses recycled ocean plastic to create Bronco Sport parts

MANILA: Ford is building on its reputation as a leader in sustainability by becoming the first carmaker to use 100% recycled ocean plastic in the production of automotive parts.

The wiring harness clips on the Ford Bronco Sport are made of ocean-harvested plastic, commonly known as “ghost gear.” The nylon material has the same strength and durability like that of previously used petroleum-based parts. However, it provides 10% cost savings and requires less energy to produce. This is a big step toward the company’s goal to make more parts our of recycled ocean plastics for other models.

“This is another example of Ford leading the charge on sustainability. It is a strong example of circular economy, and while these clips are small, they are an important first step in our explorations to use recycled ocean plastics for additional parts in the future,” Ford Vice President of Research Jim Buczkowski stated.

According to Pew Charitable Trusts, a global non-government organization, up to 13 million metric tons of plastic end up in the ocean every year, endangering marine life and polluting shorelines. Much of this is due to the fishing industry’s dependence on plastic fishing nets and other equipment due to the material’s durability, light weight, buoyancy, and low cost. The same qualities contribute to the creation of ghost nets, a growing threat to marine life. Ghost gear entangles fish, dolphins, seals, sea turtles, and birds and accounts for almost 10% of all-sea based plastic waste.

The Bronco Sport’s wiring harness clips which weigh around five grams, latch to the sides of the second-row seats and guide wires that power side-curtain airbags. According to a test conducted by Ford, the material is as robust and sturdy as petroleum-based clips despite being exposed to saltwater and sunlight.

DSM Engineering Materials collects the plastic material from the Indian Ocean and Arabian Sea, helping create jobs during the development process. A wide range of consumer goods are made from plastics gathered from the oceans, but vehicle parts have not been included until recently.

DSM starts the process by collecting abandoned nylon fishing nets. The plastic is washed of saltwater, dried, and extruded into small pellets, which are then injection-molded into the required clip shape by supplier HellermanTyton. Ford is already designing additional parts using recycled ocean plastics, such as transmission brackets, wire shields, and floor side rails — all stationary parts that the material may meet or exceed in terms of strength and longevity.

HellermanTyton Automotive Product Manager Anisian Peterman said, “As a global leader in cable management innovation, HellermannTyton strives for eco-friendly ways to pave the path to a more sustainable future. Developments like this do not come easy, so we are proud to collaborate with Ford in support of a unique product solution that contributes to healthier oceans.”

Ford has been producing automotive parts out of recycled plastics that have not been collected from the oceans for more than two decades. The carmaker has recently started to use recycled water bottles to create lightweight, aerodynamic-enhancing, noise-reducing underbody shields for the 2020 Ford Escape.

Parts manufactured using recycled ocean plastic open up new possibilities and add to a global effort to minimize ocean waste that harms sea life, or when harvested, adds to landfill congestion.

Images from Ford

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