How the Mach-E frunk was redesigned and simplified

[phidauex]

1. 2021 featuring a plastic divider insert that makes the frunk useless (to inhibit putting a baby inside).

I know, its crazy, I mean it never even stopped me from putting the baby in there - just sort of sit them up and lean them against the divider, toss some foam and a few marshmallows in there and you are good to go.

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[silverelan]

You don’t need a consultant to tell you that the original frunk is badly designed.

The original frunk should have never been released for production. You have to question where the DFM and D/ PFMEA engineers were during the release process and why there wasn’t a peer review done (like it is standard in the auto industry). Many internal product design processes were severely broken for that original design to be signed off on.

But this example is a very effective illustration by Monroe.

if you watch the original Mach-E reveal videos from late 2019, you’ll hear the team back then led by chief engineer Ron Heiser talk about how they had basically 18 months to redesign their compliance car project to turn it into the MME. A lot of decisions were made in the interest of speed rather than efficiency.

 

[RVAtom]

I know there was at one point an issue with the frunk latch getting stuck between open and not if you used the electronic latches. Is that still an issue or did one of the software updates fix that?

 

[kdonnel]

Isn't this actually bad for the consumer? One giant piece that breaks and you have to replace the entire thing. Different parts and something breaks and you can replace just that part.

It is probably cheaper from a manufacturing and assembly perspective but too many things are like this now and just have to be tossed when it breaks because they are unrepairable.

 

[litlsea]

I have watched Monroe for years and their tear downs are eye opening. When they did the Mach e their analysis was insightful. Compared to a Tesla the Mach e had so many more connections and fasteners and a mile more wire. This all led to a more expensive car that lost money for Ford. I like the frunk until I have to change the 12v battery.

 

[DesignMatters]

And that sucks, IMO. Especially after Ford made a big to-do about having a frunk for their upcoming UEV Truck. I use mine Ford and would hate to have to clutter up a trunk with the stuff I use the frunk for.

Then check the option box for it. You’re an outlier — few people use the frunk
In a vehicle with a large covered and secure cargo area. A frunk makes a lot of sense in a 911 or pickup truck, not a roomy hatchback.

 

[Mr. Toejam]

Isn't this actually bad for the consumer? One giant piece that breaks and you have to replace the entire thing. Different parts and something breaks and you can replace just that part.

It is probably cheaper from a manufacturing and assembly perspective but too many things are like this now and just have to be tossed when it breaks because they are unrepairable.

It can be. I would say most OEMs try to design so that things don’t break, “quickly”. If it affects the COO, Cost of Ownership, then they make the part cheap and easy to replace. That should be defined in the design specs and it should be a parameter in your DFMEA. Companies like Monroe aren’t always privy to all of the design specs, especially when it comes to the marketing aspects and use case of a vehicle.

The manufacturing engineering in me loves to see, and is amazed when things like a mega casting comes out. But the farmer genes in me freaks out when things like a me casting comes out. How do you repair it? Can you repair it? How can I afford to repair it? So it’s a case by case situation on how far you go.

There was an interview one time where Elon said he wasn’t worried if the mega casting gets cracked. I think he said a Tesla customer which just go in by another Tesla. That’s the attitude of a lot of startup companies that I’ve worked at and that’s why I stopped working at startup companies.

I really don’t watch too many Monroe live videos. When I do, I’m watching them because I’m interested in how things come apart and go back together. But honestly, I turned the volume down. There is a high amount of arrogance in their videos. there’s definitely educational information in there and entertainment value. But in the end, a lot of their videos are commercials for their company trying to sell their services.

 

[McSquashy]

Oh, btw. Ford had four unique designs for Mach-E frunks:
1. 2021 featuring a plastic divider insert that makes the frunk useless (to inhibit putting a baby inside). This one lacked a working release button (at least for a while)
2. 2022 / 2023 which is depicted as the original design in the video
3. 2024 which is the large, simplified / redesigned frunk in the video
4. 2025 / 2026 smaller frunk to accommodate the heat pump

My 2023 built in June has the revised and simplified frunk that's shown second in the video.

 

[Rustic Roads]

There is a high amount of arrogance in their videos. there’s definitely educational information in there and entertainment value. But in the end, a lot of their videos are commercials for their company trying to sell their services.

Agreed. The tear-down videos were fascinating, but when Sandy got on his whine-rants, it was off-putting. It's one thing to suggest that something could be done another way, but it's another to rant about this, that, or another thing, all of which he was not involved with and therefore, couldn't speak to the conditions and limitations encountered during its design and manufacturing. He drank the Tesla Kool-Aid pretty hard and I just stopped watching the videos altogether.

As a design engineer (electronics and software), I know that there are many considerations that go into a final product. There are competing goals from the various disciplines (marketing/sales, engineering, manufacturing, testing, and support/repair). The end product is a compromise of all those disciplines to make and sell the best product possible at a price that people are willing to pay and in a timeframe that makes it marketable.

There are plenty of things that could and should be better about the Mach-E, but I went into my purchase (lease) knowing what I was getting. Every vehicle is a matter of trade-offs, as there is no perfect vehicle that delivers every possible feature, reliability, and an attractive price. Munro's videos were part of that knowledge, but too many consumers put too much stock in his commentary and declared themselves experts in vehicle design and engineering.

Thank you for adding your perspective on the issues that are possible in the manufacturing side of things!

 

[Kamuelaflyer]

In a vehicle with a large covered and secure cargo area

Smashing glass is a whole lot easier and faster than prying open the hood. The trunk area is far from secure.

 

[GreaseMonkey]

My 2023 built in June has the revised and simplified frunk that's shown second in the video.

Ok, maybe 2023 job 2 was the transition point. Thanks for the correction. I’ll update my post.

 

[WallyS56]

By questioning the original design—filled with extra covers, fasteners, and brackets—Munro developed a simpler, more cost-effective solution that demonstrates the power of Lean Design.

I love the frunk on my 2024 and use it all the time. But with the addition of the heat pump, the utility is greatly compromised. The burn here is charging $500 for what is essentially a package tray.
And how many people special order their vehicle nowadays? The dealerships are going to determine how many Mach Es get the abbreviated frunk.

 

[ChehRob]

I'll bet there will be an aftermarket for about $150 unless Ford sabotages that space if you don't pay the $500 ransom.

 

[Teslaeata]

I'm sure the points made from an engineering point of view might be valid. But from a consumer's experience, the Frunk of my 2023.5 GTPE is absolutely brilliant! And it is often the catalyst to strangers being drawn in for a closer look and some answers to the brain tease it afforded them.

Both grocery runs and the 30lb propane tank fill-run are almost a guarantee.

Never had anyone mention the engineering shortcomings or the extra $25 I apparently forked over.

The thing is, apart from the egotists with a point they’re trying to make and a benefit they’re trying to achieve, who gives a monkey’s

 

[kltye]

I still have my dividers in my '21 Job 1 and I use the frunk A LOT. Takeout, additional charging cables/adapters (my Bosch VCI for FDRS lives in there), headrests when I need max space in the cabin with the seats folded, etc. We're a single-car family, so it's a do-everything car for us and I have no complaints about it, apart from maybe needing a few cm of space here and there. The cupholders are fantastic spots not just for cups/bottles, but also for small bits and pieces when working on the car.

I guess it all depends on the life you lead. If you're all about being prim and proper and have things super organized, don't have messes, don't have leftovers or have LOTS of leftovers, and don't feel the need to carry 120v and J1772 extension cords, then the frunk is probably a lot less useful.

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