The 2025 Ford Expedition marks a new chapter for the full-size SUV, and much of its story lies in the design process rather than the spec sheet. Developed with what the team calls a “Blueprint for Adventure,” the vehicle reflects a balance of function, versatility, and aesthetics shaped by extensive sketching, prototyping, and collaboration between designers and engineers.
Sketching was the foundation of the creative process. Designers used quick pen-and-paper sketches, digital drawings, and even virtual reality modeling to explore ideas. These ranged from emotional concept sketches to detailed technical illustrations, gradually refining bold ideas into features that could be engineered into reality. “Freehand sketching is important early because there are few limitations—ideas flow freely before they’re adapted to something feasible,” said Creative Designer Chad Phillips.
One of the Expedition’s most distinctive innovations is the Ford Split Gate, a reimagined liftgate designed to blend the convenience of an SUV with the utility of a truck. Three-quarters of the gate opens like a standard liftgate, while the bottom quarter folds down like a tailgate, improving cargo access and tailgating possibilities. Exterior designer Jill Dougherty described it as a chance to create “something that not only functions differently but also adds a unique look.”
Inside, the team focused on flexibility. The new Cargo Management System allows the rear area to be configured as seating, storage tiers, or even a makeshift table—an approach the designers call “Linger Longer,” encouraging owners to use the SUV as a space to gather rather than just a way to get from place to place. Senior Interior Designer Micah Jones noted the collaborative process behind it: “We pushed the design again and again, always asking, ‘what else can we do?’ until we had something that created a full tailgating experience.”
Other practical touches include Zone Lighting, which divides the exterior into four controllable light zones, useful for camping setups or night events. The Expedition also features the Flex-powered console, designed to provide adaptable storage and ergonomics, and a cabin aesthetic intentionally distinct from Ford’s trucks. Interior lead Erwan Besancon guided a theme meant to feel progressive and welcoming, emphasizing wide seats, soft materials, and a less utilitarian layout.
The Tremor package builds on the design story with enhanced off-road capability. Higher ground clearance, protective bash plates, chunky tires, and dedicated off-road lighting give the Expedition Tremor a tougher stance and the tools to travel deeper into rugged environments. Dougherty, who focused on Tremor’s development, said she was most excited by how it would “enable people to go further into the wilderness.”
On the outside, a coast-to-coast signature lighting design reinforces the SUV’s presence, while carefully detailed elements like the roof rack and taillamps demonstrate the integration of design and engineering. Phillips emphasized that close collaboration with studio engineers ensured concepts were not only bold but also achievable in production.
Technology also plays a key role. The Ford Digital Experience allows passengers to access streaming content, games, and apps when stationary, expanding the Expedition’s use beyond travel. Combined with new personalization options and the rugged design improvements, the SUV is meant to be as much a living space as a means of transport.
Design Manager Stuart Jamieson summed up the Expedition’s identity through its lighting and overall presence: “It creates a sense of premium, bold strength when seen driving down the road.”
Taken together, the 2025 Expedition is less about incremental updates and more about rethinking what a large SUV can be. From the Split Gate and reconfigurable cargo space to the refined interior and Tremor’s off-road upgrades, the model reflects Ford’s effort to deliver a vehicle that adapts to both daily use and extended adventure. The blueprint the designers followed emphasizes versatility, connection, and creativity—principles sketched on paper and realized in the details of the finished vehicle.
