Wiring harness clips in Ford Bronco Sport models are made of ocean-harvested plastic — commonly referred to as “ghost gear”
Dearborn, Mich.—Consumer products made from recycled ocean plastics include everything from sunglasses and T-shirts to running shoes and yarn. Now, Ford is is the first automaker to use 100 percent recycled ocean plastics to produce automotive parts.
Wiring harness clips in Ford Bronco Sport models are made of ocean-harvested plastic — commonly referred to as “ghost gear.” The strength and durability of the nylon material equals that of previously used petroleum-based parts but with a 10-percent cost savings and requiring less energy to produce. The small parts represent a large first step in the company’s plans to produce other parts of recycled ocean plastics on other models.
“This is another example of Ford leading the charge on sustainability,” said Jim Buczkowski, vice president of research and Henry Ford technical fellow. “It is a strong example of circular economy, and while these clips are small, they are an important first step in our explorations to use recycled ocean plastics for additional parts in the future.”
Invisible to vehicle occupants, the Bronco Sport’s wiring harness clips, which weigh about five grams, fasten to the sides of the Bronco Sport second-row seats and guide wires that power side-curtain airbags. Despite spending time in saltwater and sunlight, the material is as strong and durable as petroleum-based clips, Ford testing shows.
Items produced using plastics collected from the oceans include a wide range of consumer goods, but not until now have automotive parts been on that list.
The process begins with harvesting discarded nylon fishing nets. The plastic is washed of saltwater, dried, and extruded to form small pellets, which are then injection-molded by supplier HellermannTyton into the desired clip shape. Ford is already planning additional parts using recycled ocean plastics, including transmission brackets, wire shields and floor side rails — all stationary parts with strength and durability demands that the material can meet or exceed.
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