1. Implementation of Rice Hulls launched on 2014MY F150
Replace talc
45,000 pounds of hulls used in the first year. PP compound reinforced with rice hulls is being used to replace talc reinforced PP in an electrical support bracket in the Ford F-150.

2. Implementation of Cellulose Fiber on Lincoln MKX1
Origin
Cellulose is extracted from sustainably grown and harvested trees and related forestry byproducts, such as chips 2
Structure
Cellulose fiber, found in plants and trees, is one of the most common organic compounds in the world. Its fiber provides excellent reinforcement for plastic composites
Semi-structural armrest substrate; REPLACE GLASS FIBER with a natural fiber
Now, holistically looking at possible reinforcements 4
Implementation
The first use of cellulose fiber for a structural component 3
Performance
Ford has validated cellulose reinforced plastics – supplied by forest products leader Weyerhaeuser – for performance, durability, and thermal resistance for interior components

3. Natural Fibers Life Cycle Assessment
Raw Material
Production
“Cradle-to-Grave”
“Cradle-to-Gate”
-Often metrics from different portions of the life cycle are used to understand sustainability
-From a raw material perspective—natural fibers are derived from renewable energy (+)
-From a cradle-to-gate perspective (i.e. all processes needed to produce and assemble the vehicle)—kenaf travels huge distances (from Bangladesh) (-)
-Complete life cycle perspective (cradle to grave)—considers these factors as well as the impact on vehicle performance (i.e. lightweighting)
-To truly understand the implication of natural fiber composites and to avoid “unexpected consequences” we need to consider the impact on the whole vehicle system over time
Fiber & Resin
Production
Part
Manufacturing
Sourcing
Transportation
Use
Phase
End of Life
Life Cycle Stages

4. 2013 Fusion Grille Shutter Housing
LCA of Natural Fibers Composites
Global Warming Impact of Natural Fiber vs. Glass Fiber
2013 Fusion Grille Shutter Housing
-Natural Fiber Composites reduce life cycle GHG emissions due to carbon sequestration during fiber production and lightweighting effect in vehicle use.
-relative to the glass fiber part, the lightweighting benefit is significant and the fuel savings associated with the lighter part contributes a great deal to the improved performance
-the transportation of kenaf is a relatively small impact

5. Natural Fiber Composites
Sustainable Materials Portfolio
castor
soy
palm
Bio-based Foams
algae
wheat straw
cellulose
Natural Fiber Composites
coconut
Oat hulls
bamboo
Recycled Materials
jeans
bottles
money
fermentation
sugarcane
corn
dandelion
Bio-based Resins
Ford recently announced able to demonstrate plastics made from carbon dioxide as a feedstock (ethanol or electricity/coal plants)- concentrated CO2 from manufacturing process; inserting C02 as the ester linkage in a polyester (could make PET, PU)- Novomer
In conclusion…. Main take-away points from presentation
Ford has a science-based Sustainability Strategy
Ford has long history of eliminating SoCs ahead of regulation
Ford supports the principles of Green Chemistry and continues to research and develop sustainable solutions!
Renewable Elastomers

6. Potential applications
Vision for Sustainable Rubber
1.) Domestic sources for elastomers
2.) Renewable fillers
3.) Bio-based extender oils
Russian Dandelions
Guayule Shrub*
Bioisoprene (Biomass)
Potential applications
Corn Starch
Recycled Tread
Cellulose Ester
There are many options out there to incorporate sustainable materials into the tire tread. Industry wide materials research includes alternatives to natural rubber such as:
Russian Dandelions
Guayule
Bioisoprene
There are also several options for renewable fillers and oils.
*photos courtesy of USDA
Orange Oil
Tall Oil*
Soy Oil* 6

7. Automotive Elastomer Parts
Ford Confidential
Automotive Elastomer Parts
Elastomers are used in hundreds of parts in a typical vehicle including:
Door weather strips
Glass run channels
Gaskets and seals
Engine mounts
Hoses and tubing
Floor coverings and mats
Splash and underbody shields
Suspension bushings
Tires

8. New Materials Development Process
Physical and Mechanical Properties
Cost and Material Availability
Tire and Rubber Testing
Materials Development
Laboratory Predictors
Vehicle Evaluations
Formulation & Processing Challenges

9. Sustainable Natural Rubber
Partnering with OSU –OARDC to develop Russian dandelion and guayule as a domestic source for natural rubber.
Researching rubber formulations and performance using alternative sources to hevea natural rubber.
Founding member of P.E.N.R.A. (Program of Excellence for Natural Rubber Alternatives) consortium, with industrial and university members.

10. Research Project: Soy Oils in Natural Rubber
USB sponsored project
Target: Tip Insert (“Slap Pad”)
Durability and squeak are critical requirements

11. Research Project: Soy Oils in Chlorinated Polyethylene Rubber (CPE)
USB sponsored project
Target: Fuel Hose Covers
Must pass WSS-M96D33-12 specification
Outer protective layer to provide resistance to heat, ozone, and abrasion

12. Success: Renewable Materials
Renewable feedstocks in production at Ford today
soy
jute
castor beans 8
wheat straw
rice hulls
kenaf
coconut
cellulose

13. A Corporate Philosophy…

14. The Power of Collaboration
Universities
Research
Farmers
Resin Producer
Chemical Companies
NGOs
Tier 1
Non-Competing Partners

15. Our Heritage
“I am looking for a lot of people who have an infinite capacity to not know what can’t be done”
Now and then, I wonder what Henry Ford would think of everything his company is doing, in the effort to improve how people use and interact with their cars.
On one hand, our founder was a no-frills guy who thought black was a good enough paint color for everyone.
On the other hand, Henry Ford was also an imaginative visionary who said, “I am looking for a lot of people who have an infinite capacity to not know what can't be done.”
Though our ideas about what a car can be may have changed since Henry was with us … I’m here today in search of the same thing he was …
Ford is still looking for a lot of people who don’t know what can’t be done.
People with big ideas … like all of you.
(PAUSE)

16. Thank you for your attention!
Any questions?