Today's Ford's powertrain cost operations is slashed by the discovery of its revolutionary software called VAC. Virtual Aluminum Castings or VAC software was developed by Ford to aid in designing cast components. Said software is capable of pointing out potential stress points in parts for cylinder heads and engine blocks while they are still on the drawing board. Hence, the process is made simplified and more effective.

VAC cuts down the expenses allotted for Ford car parts design purposes. Aside from that, the trial and error stage is spared. Hence, the automaker can save so much time which can be used for other vehicle manufacturing needs and demands.

The VAC software has helped Ford create the new 3.5-liter V-6 engine's cylinder head. It is used to power the new Ford Edge. With VAC software, the process for casting engine parts is made easier and uncomplicated. The traditional and complex process which includes designing a mold, filling it with hot liquid metal, cooling and more is made undemanding. VAC uses advanced thermodynamics, metallurgy and design to make the previously complex and expensive undertaking, simple and easy.

According to Steve Matera, Ford's systems supervisor for the engine, "The use of VAC enabled a flawless launch, and reduced our development time by four months."

John Allison, senior technical leader at Ford Research and Advanced Engineering also noted, "VAC is revolutionizing the way Ford develops cast aluminum components. We now have the capability to ensure the feasibility of a given design without actually casting a part. The result is increased quality and significantly lowered costs."

VAC technology was used in developing more than 10 engine programs and it was reported that the total amount of savings amounted to more than $90 million.

Dr. Charles Wu, director of Manufacturing and Vehicle Design Research and Advanced Engineering "VAC is a major accomplishment which demonstrates how Research and Development can work collaboratively within the Ford technical community. It is user friendly software that has been transferred to computer-aided engineering groups worldwide."