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2015 FORD F-150 SUPERCREW EARNS 5-STAR TOP GOVERNMENT CRASH RATINGS THANKS TO 31 NEW SAFETY-RELATED INNOVATIONS
by Staff Report


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National Highway Traffic Safety Administration awards 2015 Ford F-150 SuperCrew with its five-star Overall Vehicle Score in New Car Assessment Program, the highest possible rating, making it the safest F-150 ever. All-new F-150 safety features include an advanced restraint system with dual-stage airbags, Curve Control to help drivers stay on their intended path, and available inflatable rear safety belts in SuperCrew models – a segment-first innovation.







The all-new Ford F-150 SuperCrew has earned the government’s highest possible crash safety rating – adding to the F-150’s strengths as the toughest, smartest, most capable F-150 ever.



Thanks to 31 new safety-related innovations developed by the Ford truck team, the 2015 F-150 SuperCrew has earned a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration’s New Car Assessment Program.



“The five-star safety rating is a terrific example of One Ford collaboration and innovation,” said Raj Nair, Ford group vice president, Global Product Development. “Our truck team worked together for years to deliver this accomplishment, using an unprecedented combination of advanced materials throughout the all-new F-150. The 2015 model is engineered to be the safest F-150 ever, which matters to customers who depend on this truck to not only get the job done, but also get them safely home.”



F-150’s improved performance is enabled by up to a 700-pound weight savings through the use of high-strength steel in the frame; high-strength, military-grade, aluminum alloy in the body; and smart engineering.



A cross-functional group comprised of Ford truck product development veterans and researchers worked to precisely optimize vehicle weight savings and manufacturing design to deliver improved durability, capability, fuel economy and crashworthiness. The team created and patented new structures, materials and joining methods that were tested virtually with supercomputer simulations, then retested in Ford’s advanced laboratories to engineer the safest F-150 ever.



Supercomputers for safety

The F-150 team started engineering the truck with supercomputers before the first units were ever even crash-tested in a lab.



Engineers developed digital safety models with nearly 1.4 million separate elements to examine how even the smallest parts of the truck would perform in a crash situation.



Safety improvements to the aluminum-alloy body

Ford’s advanced research and safety teams worked together to engineer F-150’s high-strength, military-grade, aluminum-alloy body structure to manage what happens to the body in the event of a crash.



The truck’s cab features hydroformed roof rails that constitute a cage-like structure around the doors, extruded roof bows to provide lateral strength across the top of the cab, and extruded rocker rails near the bottom to reinforce lower body strength.



How various parts of the truck were joined also yielded safety improvements. In many cases, welding was not the most effective way to join parts, so the team developed and patented methods to connect parts using high-strength adhesives. This resulted in structural strength equal to or greater than traditional welds.



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