Ford turns to chocolate bar to develop lighter plastic components

We’ve seen the world’s first Formula 3 car running on a fuel derived from waste chocolate, and now engineers at Ford have turned to the tasty treat for inspiration to produce lighter plastic parts for Ford’s vehicles. Plastic parts have traditionally been a difficult area to save weight without sacrificing strength and durability, but by looking to the Aero chocolate bar they have produced a lighter plastic by introducing gas bubbles into the plastic as it is molded. The result is a microscopic honeycomb structure that Ford says saves weight by reducing the amount of plastic used without compromising the integrity of the part.

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