Ford is Using Giant Unicastings to Build Fathom. Here’s Why That’s a Gamechanger

What’s New?

More than 5,000 giant unicastings have now been produced at Shelbyville Technical Center and are being tested or sent to Louisville Assembly Plant to support Ford Fathom prototype builds.  

What Is a Unicasting, and Why Is It So Important?

Ford’s new midsize electric truck will feature a pair of large unicastings, structures that reduce mass and improve overall energy efficiency.  This radical parts simplification reduces 146 welded steel parts to just two. 

At Shelbville Technical Center, we’re testing the unicastings to learn how to optimize the production process.  

How Do the Unicastings Fit Into the New UEV Production System?

The unicastings help make Ford's new Universal Production System possible. The new system splits a traditional assembly line into three main branches, allowing vehicle sections to be built in parallel, simultaneously, before they’re then assembled into a fully assembled vehicle. Check out previous @FordOnline coverage for more on the UEV production system.  

Right now, the team is obsessively reducing cycle time of the unicastings for efficiency. Each unicasting goes through rigorous quality checks before leaving for Louisville Assembly Plant as it moves towards the launch next year.  Ford’s unicastings have been specifically engineered for modular repairability.

Where Can I Learn More?

Check out the video below for a peek at the unicasting production process, or head to From the Road for an in-depth look at how the unicastings are made.