Auto blog

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.

How Ford plans to handle insurance and repair questions surrounding new aluminum-bodied F-150

Building a car out of aluminum has a number of benefits - the lighter weight allows the vehicle to be more agile, more fuel efficient, make better use of its power and be more resistant to dings and dents. The downside to the advanced construction, though, is that repairs are both challenging and expensive. That's troubling for the new, aluminum-bodied Ford F-150, because it's kind of made a name for itself as a rugged, durable work vehicle.
How will the legions of Ford buyers cope when it comes time to insure and repair their new trucks? Well, according to Ford, it's expecting a ten-percent jump in insurance costs for the aluminum-bodied F-150, although Ford's truck marketing manager, Doug Scott, was quick to point out that the F-150 is generally cheaper to insure than its competition from Ram and General Motors. "At the end of the day, that's sort of a wash," Scott told Automotive News at last week's Detroit Auto Show. "We've spent a lot of time and feel very comfortable that that's not going to be an inhibitor."
The other issue facing Ford is the distinct lack of body shops that have the training or equipment to repair aluminum-bodied vehicles. AN cites an estimate from the Automotive Service Association claiming that of the 30,000 independent body shops in the US, less than 10 percent are able to work on aluminum.

2016 Ford Focus RS mule spotted on US soil

Okay Ford, this is what we like to see. One of our intrepid spy photographers has captured a vehicle that we weren't even sure would see the light of day - the next Focus RS. While this is pretty clearly a mule based on the current Focus ST, as our spy points out, there are a number of giveaways about this hot hatch's true nature.
Indication number one that all is not right with this Focus is the heavily camo'd front fascia, which has been completely reconfigured for duty on the RS. It boasts significantly larger grilles that are meant to accommodate what is likely the 2.3-liter, turbocharged four-cylinder that's destined for the 2015 Ford Mustang. Considering that, then, we can expect around 300 horsepower and 300 pound-feet of torque from the hottest of Foci, although it's entirely possible that the production model could climb even higher, to around 330 hp.
The front fascia tweaks are complemented in the back by a modified rear bumper, which fails at hiding a pair of exhaust tips quite unlike the standard Focus ST's center-exit exhaust. Other obvious changes include the wheel/tire/brake package on this particular car. Larger 19-inch wheels are shod in super-sticky Michelin Pilot Super Sport tires in 235/35/19 while the brakes feature what we think are four-piston calipers, possibly from Brembo, up front.