PRETORIA, SOUTH AFRICA, 22 January 2025 – In an era where performance and efficiency are paramount, Ford has unveiled a cutting-edge innovation that will redefine how vehicles are developed: the state-of-the-art Rolling Road Wind Tunnel (RRWT). This advanced facility combines the latest in aerodynamic testing technology with a unique, vehicle-sized treadmill system, propelling Ford’s vehicle development into a new era, from electric and hybrid models to the most iconic of their internal combustion engines (ICE) – the Mustang.
Breaking Boundaries in Aerodynamic Testing
Ford’s new RRWT is a significant leap forward in vehicle aerodynamics. Capable of simulating road surface and wind speeds of up to 200 mph (322 km/h), the system allows Ford’s engineers to replicate real-world driving conditions with unparalleled precision. This makes it an indispensable tool for testing and refining the aerodynamics of next-generation Ford vehicles.
Unlike conventional wind tunnels that focus solely on air speed, the RRWT introduces a five-belt rolling road system that brings the road to the vehicle, rather than the vehicle to the road. With each wheel on its own belt and a fifth belt running beneath the vehicle’s center, this design provides a comprehensive, accurate representation of drag, downforce, and tire-road interaction at high speeds. The system’s ability to simulate open-road conditions means Ford can test vehicles for both fuel efficiency and high-performance capabilities, while accelerating the design process and reducing development costs.
“Our goal is to replicate real-world conditions as closely as possible in the lab,” said John Toth, Ford’s North America Wind Tunnels Engineering Supervisor. “The more accurately we can simulate these conditions, the faster we can bring vehicles to market that are both energy-efficient and high-performing. This technology is particularly beneficial for track-ready models like the Mustang Dark Horse, which require a delicate balance of aerodynamics to optimize downforce and reduce drag.”
Mustang Dark Horse: A Testbed for High-Speed Performance
Among the first vehicles to benefit from the RRWT’s capabilities is the 2024 Ford Mustang Dark Horse. As a performance-focused variant of the Mustang, the Dark Horse demands the ultimate in aerodynamics to excel on both the road and the track. This new wind tunnel played a crucial role in refining its design, allowing Ford’s engineers to maximize downforce – a critical factor for track-ready cars that need superior grip and handling, especially when cornering at high speeds.
The Mustang Dark Horse’s aerodynamic upgrades include a redesigned front bumper, a lower valence, a custom spoiler, and exclusive wheels. These modifications enhance airflow for engine cooling, braking, and air intake, while also improving stability by reducing front lift. The lowered air spoiler and unique splitter contribute significantly to the vehicle’s downforce, ensuring it remains firmly planted on the track or road.
“We spent around 250 hours in the wind tunnel developing the 2024 Ford Mustang, including the Dark Horse model,” explained Jonathan Gesek, Program Aerodynamicist for Mustang and Bronco. “The aerodynamic enhancements, alongside other performance factors, have resulted in the most track-capable and street-capable 5.0-litre Mustang we’ve ever created.”
Revolutionizing Vehicle Development
The RRWT’s capabilities extend far beyond high-performance vehicles like the Mustang. With the ability to simulate real-world conditions at speeds that were previously unattainable in wind tunnels, Ford can now fine-tune the aerodynamics of its entire range of vehicles. Whether it’s an electric, hybrid, or traditional internal combustion vehicle, this revolutionary technology allows Ford to improve fuel efficiency, reduce emissions, and enhance overall vehicle performance.
Additionally, the RRWT enables more in-house testing, providing Ford with the flexibility to iterate faster and more cost-effectively. By simulating open-road conditions, the company can accelerate its development process while ensuring that every vehicle it produces meets the highest standards of efficiency and performance.
A New Era in Wind Tunnel Testing
As the automotive industry moves toward electrification, Ford’s Rolling Road Wind Tunnel represents a pivotal step in advancing the science of aerodynamics. This state-of-the-art facility provides Ford with the tools necessary to create the next generation of vehicles – ones that not only meet the demands of modern consumers but exceed them in terms of performance, efficiency, and sustainability.
From the roaring Mustang Dark Horse to future electric and hybrid models, Ford’s commitment to pushing the boundaries of vehicle performance is stronger than ever. With its groundbreaking RRWT, Ford is setting the stage for the next chapter in automotive innovation, one that promises to deliver more efficient, high-performing vehicles that continue to thrill drivers around the world.
