Ground-up re-engineering delivers impressive efficiency gains

The new Mack Pioneer™ is many new advances and innovations wrapped in an ultra-aerodynamic design that stays true to Mack Trucks' pioneering history and industry leadership. And it does this while looking unmistakably like a Bulldog should.

The Pioneer was designed from the ground up around the goals of extreme fuel economy for cost savings and sustainability, and driver experience, including comfort, productivity and safety. It achieves all those goals.

“The catalyst that really got this project going was the need for a competitive highway product that was aerodynamic and could meet the greenhouse gas demands of the future,” says Lukas Yates, Chief Designer for the new Mack exterior, who sits on the frontlines of development in the studio.

Mack's design team focused on every possible detail with the Pioneer to improve aerodynamics, even to the point of re-engineering how the iconic Bulldog is mounted to the hood to shave drag from the overall design. The Bulldog itself remains the same as it always has, though.

Those looking to improve fuel efficiency can immediately see the potential in the new Pioneer thanks to its cutting-edge aerodynamic design. The truck’s new aerodynamics provide leaps and bounds in efficiency.

“Aero is very powerful,” says Yates. “If you make a percentage aero improvement, you cut that percentage in half, and that is what you gain in fuel savings. To put that into perspective, we are fighting for a tenth of a percent in many cases.”

Depending on the truck specs the Pioneer’s aerodynamic improvements deliver between 3.7% and 7.2 % Fuel Efficiency Gains and aerodynamics and powertrain improvements combined deliver between 6.1% and 9.6% fuel efficiency gains. For the long sleeper, the gains are between 4.8% and 8.7% and 7.2% and 11.1%, respectively.

What type of improvements can drivers expect?

• Sloped, wedge-shaped cab and new windscreen

While the new wedge-shaped cab grabs the eye, it is also the center of aerodynamic improvements. The new windscreen boasts an aggressive angle and is sloped back to slice through the wind and disperse it behind and away from the truck.

“Everything works around the new wedge-shaped cab that supplies more room for the cab itself and the sleeper,” says Russell. “Minor tweaks can make good differences with airflow. Airflow leads to less drag and less drag leads to better fuel efficiency.”

• Redesigned front end

Pioneer's new headlights follow the contour of the raked front end. Rooftop markers and reflectors follow the same contour and feature a flush mount design. The fenders are sloped back for improved airflow.

• New ground effects

New ground effects add to the M1's look while reducing air intrusion under the truck. A gap between truck and trailer can be an aerodynamic foe, but this new design drives efficiency by adding side extenders on both sides of the cab. A gap between truck and trailer can hinder aerodynamics, but the Pioneer’s new design includes optimized side extenders on each side of the cab, which diverts airflow away from the truck and reduces drag.

• Integrated cab and sleeper

Additionally, the cab and sleeper are now one unit rather than two modules joined together. This improves aerodynamics in many ways, as well as increasing cab rigidity for more durability and adding interior space.

• Relocated grab bars

Despite the myriad design changes, entering and exiting the vehicle remains automatic. With the Mack design team relocating the grab bars inside the doors, operators not only capitalize on additional improvements in airflow and drag, but temperature and roadside elements are not a factor. The new location offers a more comfortable reach.

• Safety improvements

Safety improvements round out the cab changes with top new safety features: Mack’s proprietary Advanced Driver Assist System, new frontal and integrated driver and passenger door airbags, and digital mirrors.