Ford has redefined aerodynamic innovation with its new Rolling Road Wind Tunnel (RRWT), integrating cutting-edge wind tunnel technology with a high-speed, vehicle-sized treadmill to create the ultimate testing environment. This breakthrough facility played a pivotal role in developing the Mustang Dark Horse, Ford’s most aerodynamic and track-capable 5.0-litre Mustang ever.
Ford unveils its state-of-the-art Rolling Road Wind Tunnel (RRWT), revolutionizing aerodynamic research for next-generation electric, hybrid, and internal combustion engine vehicles.
• The RRWT’s Rolling Road surface achieves speeds of up to 200 mph (322 km/h), replicating real-world conditions to optimize performance and efficiency.
• The all-new Mustang Dark Horse benefits from advanced aerodynamic testing, achieving the highest downforce of any 5.0-litre Mustang to date.
The RRWT enables Ford engineers to simulate wind and road conditions at speeds of up to 200 mph (322 km/h). This cutting-edge technology ensures greater precision in measuring both wind drag and downforce—critical factors for achieving optimal vehicle performance. By replicating real-world conditions in a controlled lab setting, the RRWT streamlines the design process, reduces costs, and accelerates the development of efficient and performance-driven vehicles across Ford’s lineup, including electric, hybrid, and internal combustion models.
“The closer we can get to reality in the lab, the better and faster we can create energy-efficient vehicles with exceptional stability on the road and track,” explained John Toth, Ford’s North America Wind Tunnels Engineering Supervisor. “Testing with moving wheels and tires is essential for enhancing aerodynamics, especially for track-ready vehicles like the Mustang Dark Horse, which require a balance between aerodynamic drag and downforce.”
Innovative Testing with Rolling Road Technology
The RRWT features a groundbreaking five-belt system designed to replicate real-world driving conditions. Four smaller belts support each wheel, while a larger fifth belt runs beneath the center of the vehicle. This industrial-scale plug-and-play system, which can switch between single- and five-belt configurations, operates at speeds of up to 322 km/h—offering unparalleled testing capabilities for high-performance vehicles.
Aerodynamic Mastery: Mustang Dark Horse
The Mustang Dark Horse represents the pinnacle of Ford’s aerodynamic expertise. By prioritizing tailored aerodynamics, Ford engineers have created a vehicle that delivers exceptional track-ready performance. For passenger cars and trucks, the goal is often to minimize drag for improved efficiency. However, the Mustang Dark Horse trades low drag for increased downforce, ensuring superior handling and stability at high speeds.
The Dark Horse’s aerodynamic advancements include a redesigned front bumper, lower valence, rear spoiler, and unique wheels. These features are engineered to enhance airflow for engine cooling, braking, and intake systems while reducing lift. The car’s lower air spoiler and splitter are specially tuned for greater downforce, ensuring it remains firmly planted on the road or track.
“We spent approximately 250 hours in the wind tunnel refining the aerodynamics of the 2024 Ford Mustang, including the Dark Horse,” said Jonathan Gesek, Program Aerodynamicist for Mustang and Bronco. “The result is the most track- and street-capable 5.0-litre Mustang we’ve ever produced.”
Ford’s investment in advanced wind tunnel technology underscores its commitment to pushing the boundaries of automotive innovation, ensuring that every vehicle—whether designed for efficiency or performance—meets the highest standards of excellence.
