When it comes to EVs, a bigger battery isn’t always better. 

Ford Motor Company is making that bet as part of its effort to manufacture a new suite of more affordable electric vehicles—beginning with a $30,000-starting-price mid-size electric truck set to launch in 2027.

To get more out of a smaller battery, Ford has had to reimagine every step of its manufacturing process. It has scrapped the typical assembly line process in favor of what the automaker........

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