Ford Bronco Sport: Leading the Charge With Recycled Ocean Plastic Parts
How Ford Bronco Sport became the first vehicle to feature parts made entirely from 100% recycled ocean plastic, paving the way for a circular automotive future.
Ford Bronco Sport: Driving Innovation With 100% Recycled Ocean Plastic
The overwhelming issue of plastic pollution in the world’s oceans has reached a critical point, with estimates suggesting up to 13 million metric tons of plastic enter ocean waters each year. Now, Ford is taking a bold step toward sustainability by becoming the first automaker to integrate parts made from 100% recycled ocean plastic, also known as “ghost gear,” into its Ford Bronco Sport model. This achievement not only supports marine ecosystem health but also sets a precedent for environmental responsibility in the auto industry.
The Global Ocean Plastic Crisis
Ocean plastics, particularly from discarded fishing gear, are a pressing threat to marine life. Ghost gear—which includes abandoned fishing nets and lines—accounts for nearly 10% of all sea-based plastic waste. These plastics entangle marine animals such as fish, dolphins, sharks, seals, turtles, and birds, causing injury, starvation, and death.
- 13 million metric tons of plastic waste flow into oceans annually.
- Ghost gear represents ~10% of ocean plastic waste.
- Environmental impact: Plastics persist for centuries, poisoning marine food chains and littering coastlines.
With the durability, buoyancy, and low cost of plastic, the fishing industry has become a major source of ocean debris. Recovering this material not only reduces hazards to wildlife but also represents an environmental and economic opportunity.
Ford’s Commitment to Sustainability
Ford has a decades-long history of integrating recycled materials into vehicle manufacturing. Previously, the company used recycled water bottles to produce aerodynamic underbody shields in the 2020 Ford Escape. With the Bronco Sport, Ford raises the bar by introducing automotive parts made entirely from discarded ocean plastic.
- Legacy of innovation: Ford has used recycled plastics for over two decades in various models.
- Global partnerships: Collaborates with DSM Engineering Materials and HellermannTyton to process and mold ocean plastics into car parts.
How 100% Recycled Ocean Plastic Parts Are Made
The journey from ocean debris to car part is both simple and revolutionary. Here’s how Ford’s process works:
- Collection: Workers in regions including the Indian Ocean and Arabian Sea recover discarded fishing nets and other plastic materials.
- Cleaning: The recovered plastics are thoroughly cleaned to remove contaminants.
- Processing: Plastics are dried and formed into small, high-grade pellets suitable for automotive part fabrication.
- Molding: The pellets are molded into wiring harness clips—the first use case for Ford’s recycled ocean plastic—by partner HellermannTyton.
This closed-loop process is a prime example of the circular economy in action: reusing waste to create valuable, durable goods while reducing pressure on landfills and natural resources.
Introducing the Bronco Sport’s Ghost Gear Clips
The first component in Ford’s lineup produced from 100% recycled ocean plastic is a wiring harness clip, sometimes weighing just five grams. Though small, these clips represent a major leap forward in sustainable automotive design.
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- Location in vehicle: Fasten the sides of the second-row seats and guide wires for side-curtain airbag systems.
- Invisible to users: The clips are built inside the vehicle, not in visible parts, ensuring the integrity and aesthetics of the interior remain intact.
- Performance: Lab tests confirm that these parts offer strength and durability equal to, or surpassing, their petroleum-based predecessors—even after exposure to saltwater and sunlight.
- Cost savings: Production requires less energy and comes in at roughly 10% cheaper than conventional plastic parts.
| Feature | Recycled Ocean Plastic Clips | Petroleum-Based Clips |
|---|---|---|
| Material Source | Discarded fishing nets/plastics | Virgin petroleum |
| Durability | Proven equal performance | Industry standard |
| Cost | ~10% reduction | Baseline |
| Production Energy Use | Lower energy required | Higher energy consumption |
| Environmental Benefit | Reduces ocean waste | Consumes nonrenewable resources |
Why Ghost Gear?
Ghost gear, the primary material used for the Bronco Sport’s new parts, is a term for abandoned or lost fishing equipment. Its high-quality nylon composition makes it ideal for automotive applications after recycling. Ford’s approach is twofold:
- Environmental: Removing hazardous debris from oceans and shorelines.
- Social: Providing jobs for workers involved in collection and processing, often in coastal or developing regions.
Processing ghost gear not only promotes cleaner oceans but also supports local economies in affected areas.
Circular Economy and the Automotive Industry
Ford’s initiative exemplifies the principles of the circular economy—keeping materials in use and reducing waste. The success of these wiring harness clips could mark the beginning of broader shifts in the industry:
- Expansion of recycled materials to more vehicle parts, such as brackets, side rails, and other structural components.
- Ongoing research into alternative polymers and bio-based plastics for automotive use.
- Increased collaboration between automakers and environmental partners to scale sustainable practices.
Award-Winning Innovation
The pioneering use of Akulon RePurposed recycled ocean plastic in the Bronco Sport earned Ford, DSM Engineering Materials, and HellermannTyton an Innovation Award from the Society of Plastics Engineers (SPE). This accolade highlights both the technical achievement and the positive environmental impact of the project.
- The award recognizes advances in material engineering and their application in mass-market vehicles.
- It encourages further investment and R&D into sustainable material solutions.
Ford’s Future Sustainability Plans
Though the scope of this innovation currently covers wiring harness clips, Ford has made it clear that this is just the beginning. Plans are underway to incorporate recycled ocean plastics into more components, including transmission brackets and other underbody structures, across multiple vehicle platforms.
- Scaling up: Other vehicle models may soon see similar or greater integration of recycled materials.
- Continuous improvement: Leveraging lessons from the Bronco Sport project to develop even more robust, sustainable manufacturing methods.
The company’s long-term vision includes reducing its environmental footprint, promoting responsible sourcing, and inspiring industry-wide change.
Broader Implications: Consumer Goods and the Circular Economy
Recycling ocean plastics is not limited to automotive manufacturing. The global movement encompasses a range of consumer products—clothing, shoes, eyewear, and more—that integrate recycled plastic to address pollution. Ford’s move aligns with trends across industries and demonstrates how cross-sector collaboration can drive large-scale change.
- Consumers are increasingly demanding products with sustainable, recycled, or upcycled content.
- Corporations hold the potential to dramatically reduce environmental impact through commitment to circular supply chains.
- Policy and regulation may in time reinforce or accelerate such changes industry-wide.
The Economic Benefits
Beyond its ecological significance, Ford’s initiative delivers notable economic benefits:
- Lower material costs: Recycled plastic clips are approximately 10% cheaper to produce.
- Reduced energy consumption: The recycling and molding process uses less energy than creating parts from virgin materials.
- Job creation: Collecting and processing ocean plastics creates jobs, especially in coastal regions impacted by plastic pollution.
The Automotive Industry’s Path Forward
Ford’s achievement marks a transformational step for the industry but will require further innovation and commitment to scale:
- Investments in recycling technologies to handle diverse forms of plastic waste.
- Development of design standards for recycled-content parts that match or outperform traditional alternatives.
- Leadership from global automakers to set benchmarks for sustainable sourcing and manufacturing practices.
As more companies adopt similar circular economy initiatives, cumulative gains could significantly reduce the environmental impact of vehicle production worldwide.
Frequently Asked Questions (FAQs)
Q: What is recycled ocean plastic, and why is it important?
A: Recycled ocean plastic is plastic waste collected from oceans—primarily fishing nets and gear—reprocessed for use in new products. Its reuse reduces ocean pollution, protects marine wildlife, and lowers demand for new petroleum-based plastics.
Q: What part of the Ford Bronco Sport is made from ocean plastic?
A: Currently, the Bronco Sport features wiring harness clips made entirely from 100% recycled ocean plastic. These secure wiring within the vehicle, such as those for side-curtain airbags.
Q: Do recycled plastic parts perform as well as standard plastic parts?
A: Yes. Ford’s testing demonstrates that recycled ocean plastic clips offer comparable, if not superior, strength and durability compared to traditional petroleum-based parts, even after long-term exposure to saltwater and sunlight.
Q: Is Ford planning to expand the use of recycled materials?
A: Absolutely. Ford has indicated ongoing research and plans to apply these materials to additional vehicle parts and future models as processing capacities expand.
Q: Can consumers help reduce ocean plastic pollution?
A: Individual actions—such as reducing single-use plastics, supporting brands that use recycled materials, and advocating for responsible disposal—contribute to long-term solutions for ocean health.
Conclusion: An Automotive Milestone With Lasting Impact
The Ford Bronco Sport’s use of 100% recycled ocean plastic marks a pioneering achievement in automotive sustainability. By turning ocean waste into high-performance car parts, Ford is paving the way for a cleaner, more responsible future. The project’s success signals new standards not just for one vehicle, but for the entire industry’s approach to materials, environmental protection, and circular innovation.
As consumer demand for eco-friendly products grows and recycling technology evolves, developments like these will become increasingly crucial in protecting both natural ecosystems and the future of transportation.
References
- https://www.broncosportforum.com/ford-bronco-sport-becomes-first-vehicle-to-feature-parts-made-of-100-recycled-ocean-plastic/
- https://www.recyclingtoday.com/news/dsm-ford-earn-innovation-award-for-recycled-ocean-plastic-in-bronco-sport/
- https://www.jimschmidtford.net/blog/2022/february/2/the-ford-bronco-sport-is-the-first-vehicle-to-use-parts-made-from-recycled-ocean-plastic.htm
- https://www.surpriseford.com/blog/2021/december/25/ford-bronco-sport-becomes-first-vehicle-to-feature-parts-made-of-100-recycled-ocean-plastic.htm
- https://www.aptiv.com/en/insights/article/the-first-auto-part-made-from-100-recycled-ocean-plastic
- https://www.youtube.com/watch?v=Ee7S34Bf_ts
- https://www.envalior.com/en-us/insights/press-release/2021-12-08-dem-recycled-ocean-plastic-used-in-ford-bronco-earns-global-innovation-award
- https://www.youtube.com/shorts/wXWxSlilC5g
- https://www.americanindustriesgroup.com/news/ford-bronco-sport-is-first-vehicle-to-use-components-from-100-recycled-ocean-plastic/
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