Ford has revealed a state-of-the-art wind tunnel at its Allen Park, Michigan development center, instrumental in honing the performance of vehicles like the 2024 Mustang. This advanced facility is the first rolling road wind tunnel capable of generating wind speeds up to 200 mph.
The tunnel's unique feature is its five treadmill-like belts. Four belts allow the vehicle's wheels to rotate during testing, while a fifth belt runs under the center, simulating real-world driving conditions more accurately than traditional fixed-floor wind tunnels.
Visualization techniques, such as smoke and lighting, are employed to observe airflow over the vehicle's surfaces. According to John Toth, Ford's North America Wind Tunnels engineering supervisor, this realistic testing environment enables faster development of energy-efficient vehicles with enhanced on-road and track stability.
The innovative treadmill system is particularly beneficial for optimizing the aerodynamics of performance-focused vehicles like the Mustang Dark Horse, which demands a delicate balance between minimizing drag and maximizing downforce.
The Mustang Dark Horse, with its 500 hp engine, benefited significantly from this technology. The wind tunnel played a crucial role in reducing front-end lift and enhancing downforce, contributing to its superior track performance.
Jonathan Gesek, program aerodynamicist for Mustang and Bronco, revealed that approximately 250 hours of wind tunnel testing were dedicated to refining the 2024 Ford Mustang, including the Dark Horse variant.
The tunnel's impressive 7,000 horsepower turbine can move an immense volume of air—enough to fill a 250-foot blimp in a mere five seconds.
While Ford doesn't claim the Mustang Dark Horse can achieve 200 mph, the company has produced vehicles capable of such speeds, like the 2013 Mustang Shelby GT500 (202 mph) and the 2017 Ford GT (216 mph).
The primary focus for the Mustang Dark Horse was optimizing downforce, reducing lift, and enhancing cooling systems. This new wind tunnel will also be instrumental in developing future energy-efficient electric vehicles.
