Behind the Scenes | 2021 ROUSH F-150 Design Process

Have you ever wondered how a vehicle is designed and brought to market? Many of our vehicles share a similar design process but in this article, we share a sneak peek behind the design process of the 2021 ROUSH F-150. If you haven't seen the '21 ROUSH F-150 already, click HERE to read all about it.

Initial design sketches of the 2021 ROUSH F-150

There are many steps and phases within the design process that can take months before we have physical components in hand. The initial design process starts with conceptual sketches as you see in the image above. Conceptual drawings are a loose idea of the direction the designers would like to go in. These designs are taken to product strategy and marketing to approve and agree that this is the direction they want to go in. After it has been approved, our engineers and design studio collaborate to build it in CAD (computer-aided design).

Designer sketching out the ROUSH F-150's aggressive front fascia.

CAD models and structures are developed for each component. Every component can be modeled uniquely to capture proper component definition.  After the A surface (the outside surface that you see from an installed perspective) has been developed, engineers work hand in hand with designers to capture manufacturing capabilities, alignment features, proper structure for mounting, component/design features, and durability.  When the design has been finalized it then gets detailed for 2D drawings. 2D drawings capture all the critical features, specifications, and tolerances for production.

Designers going over several design elements of the 2021 ROUSH F-150.

Components are shared with other facets of the company (manufacturing, assembly, marketing, etc.) to see if they are feasible and can be used during the production process. Without reviewing components with other departments, it would be difficult to have a reliable process that is repeatable with the highest quality results. One department may have an issue with a portion of the design, while another may not. Reviewing designs with the manufacturer are extremely important because there may be design issues that prevent the parts from being manufacturable. These changes are then implemented in the 3D design.

One of our designers using a 3D printed wheel as reference to add the wheel design in CAD.

Utilizing our vertical integration with Roush Industries, we can take our designs from the computer to prototype components. We utilize Roush Industries' rapid prototyping and machining assets to create 3D printed models of components. These 3D-printed components allow us to validate and test design iterations. We can quickly alter these designs and reproduce them until we are satisfied with the outcome. (pictured above is a 3D printed wheel that made its way to the production '21 ROUSH F-150)

Clay models are utilized to give a "real-world" view of what the final product could look like.

Samples of the components are then produced and test fitted on the vehicle. We mentioned A surface earlier which is the "pretty" side of our components but there is also a B surface that engineering is heavily involved with. The B surface includes all the fastener locations, mounting tabs and structural integrity of our newly designed ROUSH components. After these components have been fitted to a vehicle we perform many rigorous tests to ensure longevity and durability. Stay tuned for more information on the 2021 ROUSH F-150 development testing next week!

Learn more about the 2021 ROUSH F-150

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Jaron Cole
Jaron Cole
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