The TH!NK Neighbor is a zero-emissions golf-cart style, electric vehicle. It features an all-welded aluminum frame, the first of its kind in the industry, which gives it improved structural rigidity for better driving dynamics and crash performance. The frame assembly is extremely difficult to manufacture, but the weight savings and exposed aluminum surface are critical to Ford’s design concept.

The precision aluminum components were extruded on the eight-inch press at the Kalamazoo, Michigan plant and then shipped to the Sidney, Ohio operations for assembly. At Sidney, the frame assembly components were cut to length and machined on the plant’s advanced CNC equipment. The components then passed through a robotic and manual welding operation. Quality checks were in place at each step of the process; 100 percent of the completed fixtures were checked for quality before shipping to the assembly plant. In addition, one frame-assembly out of every lot was cut to verify the welds.

Greenhouse components went through a special surface treatment through our finishing partner in Michigan. Continuous process management was needed to ensure high aesthetics and zero defects.

Note: Ford recently announced the cancellation of their TH!NK electric vehicle program due to sales issues. The company has instead shifted its technology focus away from electric drive and into hybrids and fuel cells.