The Ford Escape, Fusion, Mustang and F-150 all use EcoLon, a nylon resin made from 100 percent recycled carpet. Wellman Engineering Resins makes the material, and Dana Holding Corporation uses the material to make the cylinder head covers (pictured left).
So far the process has recycled an amount of carpet equivalent to nearly 154 football fields, preventing the use of more than 430,000 gallons of oil.
The carpet-based cylinder head covers join other Ford sustainable material initiatives, including its use of soy foam seat cushions and natural-fiber plastic for interior components, and recycled materials including yarns for seat covers, resins for underbody systems and recycled blue jeans for sound-dampening material.
“This single use has made an incredible impact, and we’re continuing to look for ways to expand the use,” engine design manager Brett Hinds said.
“We didn’t have to make compromises for this application,” said engine sealing supervisor Roy Ford. “With a fixed raw material cost that delivers cost savings compared to oil, along with the green benefit, this application adds to the ways Ford is minimizing our impact on the environment.”