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Recharge Wrap-up: Ford 1.0L EcoBoost a hit in Europe; Build a tiny inverter, win $1 million

In Europe, Ford's 1.0-liter EcoBoost engine is the best-selling turbocharged gasoline engine. The three-cylinder motor powers 20 percent of new Fords sold in Europe. Earlier this year, it won its third International Engine of the Year award, and between January and June, it was sold in about 120,000 cars. So far this year, 38 percent of Fords sold in the Netherlands, 35 percent in Denmark and 32 percent in Switzerland have been powered by the 1.0-liter EcoBoost. The engine's turbocharger spins at 248,000 rpm, and provides 24 psi of pressure. The engine produces up to 138 horsepower, depending on the version. Read more in the press release below. When lithium-ion battery packs are retired from the road, remanufacturing, repurposing, and recycling are worthwhile options, according to a study by Mineta Transportation Institute. The study included a cost-benefit analysis of those three options, and found remanufacturing to be the best route. To get the most out of them, batteries should be tested and have their damaged cells replaced then put back to use. Repurposing is the second best option, using the remaining available charge for something besides cars. Recycling on its own isn't profitable, but it could make economic sense with "increased technological breakthroughs." Learn more at Recycling International or download the report here. A smaller inverter for EVs can win you $1 million. The Little Box Challenge is an open competition to build a power inverter with a density of at least 50 watts per cubic inch. Google and the Institute of Electrical and Electronics Engineers (IEEE) are offering the hefty prize to the team that builds the inverter with the highest power density within an enclosed volume of 40 cubic inches. Teams must register by September 30. Read more at Green Car Congress or learn more at the Little Box Challenge website.

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.

Ford recalls over 500,000 trucks and SUVs, including Explorer, F-150, and Lincoln Aviator

For the second time in a month, Ford is recalling the brand-new 2020 Explorer and 2020 Lincoln Aviator for minor safety issues. This recall, which also affects certain 2018-2020 Ford F-150s, 2019-2020 Ford F-Series Super Duty trucks, 2018-2019 Ford Explorers, and 2019-2020 Ford Expeditions, pertains to potentially faulty seat-back reclining mechanisms. In total, the recall touches 550,186 vehicles. A mechanical part meant for relaxation and comfort has the Ford Motor Company stressin'. Ford says potentially affected vehicles might be missing the "third pawl required for seat-back strength" in the reclining mechanisms on certain seats. Because of this, the seats might not properly keep a person in place during the event of a crash or otherwise.  In the F-150s, F-Series Super Duty trucks, 2018-2019 Explorers, and Expeditions, the recall affects vehicles with manual driver and/or front passenger seat-back recliners. On the 2020 Explorers and Lincoln Aviators, rear outboard seats with manual recliners are of concern. Of the more than 550,000 vehicles, 483,325 vehicles are in the United States, 58,712 are in Canada and 8,149 are in Mexico. Thus far, Ford is not aware of any injuries from the issues. Ford says it expects most vehicles will not need repair, but dealers will inspect the seat structures out of precaution. If fault is found, dealers will replace the seat structure altogether. For this recall, Ford's reference number is 19C07. Contact your dealer for more information. Featured Gallery 2020 Ford Explorer View 47 Photos Recalls Ford Lincoln Truck SUV