The unlikely inspiration for a new weight-saving system comes from the Aero chocolate bar, whose bubbles have been recreated in plastic parts of the Ford Focus.
By injecting gas during moulding, a cross section of plastic parts in the Focus now resemble an Aero chocolate bar and helps to cut down the weight of heavy plastic parts.
The technology reduces the weight of the plastic cars by up to 20 per cent and according to Ford, will improve handling, acceleration and reduce stopping distance.
Named MuCell, the honeycomb structure has also been designed to achieve a five-star rating in EuroNCAP crash tests despite its lightweight properties.
Ford’s MuCell technology expert Carsten Starke said: “The first time I saw this plastic under the microscope I thought to myself it looks like an Aero chocolate bar! The bubbles in the chocolate change the taste, but in our plastics they save weight and making cars lighter reduces emissions and fuel consumption significantly."
The technology will appear in the Ford Focus but Ford also plans to roll it out to its other cars such as the Ford C-Max, Ford S-Max, Ford Mondeo and Ford Galaxy in the next few years.
The new Ford Focus is now on sale in the UK. Based on an entirely new platform, the family car is expected to be one of the best-selling models in the UK.
Available in Edge, Zetec and range-topping Titanium specifications, the Ford Focus comes with air conditioning, DAB radio, Bluetooth and Ford’s Easy Fuel system as standard across the range.
Prices for the new Ford Focus start from £16,000 for entry-level models, rising to £18,750 for range-topping Ford Focus Titanium models.