A little bit of the ocean built into every Ford Bronco Sport

The parts will be made entirely of ocean-sourced plastics – the nylon they are made from was once remnants of so-called “ghost gear” such as abandoned fishing nets – saving the car maker money and using less energy to produce than conventional electrical connectors.

It’s the first step in Ford’s wider plans to add more ocean-sourced recycled plastics to other vehicles in its showroom.

However, Ford’s recycling effort will be a drop in the ocean compared with the almost 13 million tonnes of plastic that is estimated to enter the world’s waters each year.

“Invisible to vehicle occupants, the Bronco Sport’s wiring harness clips, which weigh about five grams, fasten to the sides of the Bronco Sport second-row seats and guide wires that power side-curtain airbags,” Ford said. 

“Despite spending time in saltwater and sunlight, the material is as strong and durable as petroleum-based clips, Ford testing shows.”

Ford said the plastic material was collected from the Indian Ocean and the Arabian Sea by thermoplastics manufacturing specialists DSM Engineering Materials. 

After being cleaned, the recovered plastic is made into small pellets that are then injected into the moulds that form the clips.

“Ford is already planning additional parts using recycled ocean plastics, including transmission brackets, wire shields and floor side rails – all stationary parts with strength and durability demands that the material can meet or exceed,” it said.

It’s not the first time Ford has used recycled plastics in a vehicle. Its most recent application was using recycled water bottles to make underbody noise-reducing aerodynamic panels for the 2020 Ford Escape.

The Ford Bronco has not yet been earmarked for release in Australia.