What is the body material of Ford Mach-E?

The body is a mixed-material unibody that blends high-strength steel with aluminum to balance safety, rigidity, and efficiency. The exact panel-by-panel composition varies by trim and production year.

What materials make up the Mach-E’s body?

The Mach-E follows Ford’s modern multi-material approach, prioritizing a steel safety cage while using aluminum where it reduces weight without compromising strength. This combination is intended to improve efficiency, handling, and crash performance.

• High-strength steel for the primary safety structure and key load paths


• Aluminum used on select exterior panels and body components to reduce weight


• Various steel grades and alloys selected to optimize stiffness, durability, and corrosion resistance

In summary, Ford employs a mixed-material strategy—steel for the safety-critical backbone and aluminum where weight savings can be gained—throughout the Mach-E’s body to support performance and safety goals.

Why these materials matter for performance and safety

Weight management is a central consideration for electric vehicles, and the Mach-E’s mixed-material approach helps offset the weight of its battery pack. Aluminum reduces unsprung and overall weight in non-structural areas, while high-strength steel reinforces crash protection and chassis rigidity. Ford’s approach aligns with industry practice for mid-size EV crossovers, aiming to deliver efficient driving range without compromising passenger safety.

Structural backbone and panel strategy

The Mach-E’s passenger cell relies on a robust steel frame to absorb and dissipate crash forces, while aluminum components are used where feasible to trim weight. This strategy supports both energy efficiency and driving dynamics, particularly in a vehicle designed for everyday versatility and performance.

Manufacturing and durability considerations

Ford uses established manufacturing techniques—such as careful bonding and sealing of mixed materials, along with corrosion protection measures—to ensure long-term durability and consistent build quality across a range of climates and usage scenarios.

Summary

The Ford Mustang Mach-E employs a mixed-material body—primarily high-strength steel for safety-critical structure combined with aluminum in selected panels and components—to optimize safety, stiffness, and efficiency. The exact material mix varies by trim and production year, reflecting Ford’s multi-material approach common to many modern EV crossovers.

Key takeaways

- Mixed-material approach: steel for structure, aluminum for weight reduction

- Material choices designed to balance safety, efficiency, and durability

- Exact panel-by-panel composition can vary across models and production runs

What is the downside of Mach-E?

The "cons" of the Mustang Mach-E are its firm ride, limited voice command functionality, and potential software/hardware issues, though many hardware problems were resolved in later models. Other drawbacks include a cold-weather range reduction, a lack of some luxury features, and concerns over the brand's use of the "Mustang" name for this vehicle.
 
This video discusses common issues with the Ford Mustang Mach-E: 59sThe Miles DrivenYouTube · Apr 30, 2025
Performance and handling

• Firm ride: The suspension is tuned for sportiness, leading to a firm ride that some find uncomfortable, especially on bumpy roads. 
• Firm ride on bumpy roads: The ride can be bouncy on rough roads, which may not be ideal for a family vehicle. 
• Cold weather range loss: The lack of a heat pump results in a significant reduction in range during winter. 

Technology and interior

• Limited voice commands: Voice commands have very limited functionality, primarily for changing stations and adjusting temperature, requiring users to navigate menus for other tasks. 
• Lack of physical buttons: There are few physical buttons, which some owners find inconvenient for frequently used functions like the trunk. 
• Basic interior: The interior can feel spartan for a vehicle in its price range, with a lot of plastic and a lack of ventilated seats. 
• Software issues: Some early models experienced software glitches, such as charging cutoffs not working as programmed. These issues were often resolved through over-the-air (OTA) updates or dealer diagnostics. 
• Inconvenient trunk release: Opening the trunk can require navigating a menu on the touchscreen, which some find cumbersome. 
• Finicky phone-as-key: The phone-as-key feature can be unreliable and has stopped working for some users after app updates. 
• Limited instrument cluster: The instrument panel lacks the ability to display basic information like tire pressure or detailed efficiency data. 

Other

• Charging port location: Some users find the location of the charging port to be inconvenient. 
• Rear rotor issue: Some 2021 vehicles experienced an issue where the rear rotors would score themselves if the car wasn't driven frequently enough. 
• Inconsistent OTA updates: While OTA updates fix some issues, they can also sometimes change settings, requiring users to re-configure them. 
• Ford's use of "Mustang" name: Enthusiasts of the traditional Mustang model may find the use of the name for this crossover bothersome. 
• Limited off-road capability: The car has limited ground clearance and lacks off-road modes, making it difficult to navigate challenging terrain. 

You can watch this video to learn about the pros and cons of the 2024 Ford Mustang Mach-E GT: 1mDiscerning CarsYouTube · Aug 25, 2024

What is the Mach-E body made of?

Mustang Mach-E 1400
It is made mostly from composite fiber, saving more weight over carbon fiber.

Why is Ford discontinuing Mach-E?

The Ford Mustang Mach-E isn't selling well due to a combination of issues, including a recent stop-sale order caused by a software defect that can trap occupants, previous recalls for safety-related problems, and broader market factors like intense competition and a high price point. While Ford has tried to boost sales with discounts, the vehicle still faces slow sales compared to its competitors and the industry average, notes CarBuzz.
 
Immediate and recent issues

• Stop-sale order: In June 2025, Ford halted sales of the Mach-E because a software defect could cause the doors to malfunction, potentially trapping occupants inside or outside the vehicle. 
• Recalls: The Mach-E has been the subject of multiple recalls for various issues, including a potential for the vehicle to not start or lose power, improper seat belt attachments, and loose subframe bolts. 

Broader market factors

• Competition: The Mach-E faces stiff competition, particularly from the Tesla Model Y, which is often seen as a more affordable and popular alternative. 
• Pricing: The Mach-E's higher price point, even with discounts, makes it a harder sell than some competitors. 
• Depreciation: EVs, in general, tend to depreciate faster than internal combustion engine vehicles, which can deter potential buyers. 
• Market slowdown: The entire new car market has experienced a slowdown, with even the Mach-E's slower-than-average sales pace contributing to dealer inventory challenges. 

Does the Mach-E have real leather?

Does the Mustang Mach-E have real leather seats? This EV does not use traditional leather in any trim level. Instead, it features premium Ford ActiveX synthetic seating material, which offers superior durability and ease of maintenance while providing a premium feel and appearance similar to leather.