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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Why the 2015 Detroit Auto Show will be the best since The Crisis

The Detroit Auto Show clearly has its swagger back, and the 2015 edition will be a veritable feast for the enthusiast senses. We're talking serious performance, and it will be exhibited in a variety of forms. Sports cars. Supercars. Muscle-bound luxury cars. They're all set for splashy debuts in January in the Motor City. It's another signpost that companies have recovered from the global economic crisis that gripped the industry from 2008-09. For a while, automakers played it safe at Detroit and other shows. Environmentally friendly cars were important, especially for General Motors and Chrysler that were living on loans from Uncle Sam. Ford, Toyota and other companies generally focused on their best-selling or core models. With a few notable exceptions, recent auto shows have been a bit more buttoned-down than in the past. Boring probably isn't the right word, but austerity has been reality. That's changing. Car companies are making money. Sales are up. Aside from the many nagging recalls – and they are notable – the industry now has the time and energy to make performance cars a priority. That will be offered in hard evidence in Detroit. A year from now when we look back at this auto show, we'll sum it up with one word: Horsepower. But make no mistake, this isn't frivolous. Sports and luxury cars are expensive. They're profitable. They boost images and highlight strengths. With that in mind, here are five significant performance-oriented reveals to watch for when the show kicks off in less than two weeks. 2016 Acura NSX Acura's reborn NSX is a strong bet to earn plenty of votes for our Editors' Choice awards. It's one of the most anticipated – and strung-out – reveals of the year. Think back: we actually saw an NSX concept at the 2012 Detroit show, and Acura has spent the last three years teasing the car in a variety of ways. The slow burn, however, means we know a lot about the NSX. It's will use a mid-mounted twin-turbo hybrid powertrain and run with all-wheel drive. It will also wear an innovative zirconium e-coat paint, a new paint process that Honda says is more environmentally friendly. Honda has also said it will build the new NSX in Ohio, where a large part of the car's development work has been done. The original NSX was produced from 1990-2005 and helped establish Acura's performance credentials in the United States. It was a landmark car and a shot across the bow of Ferrari, Lamborghini and others.

This is what a 3D-printed liquid metal Ford Torino looks like

Artist Ioan Florea has encapsulated a 1971 Ford Torino with 3-D-printed liquid metal transferred onto the car using technology that he developed, and the result is a stunningly shiny, seamless design.
"The surface has the highest coefficient of reflectivity never achieved before," Florea told us in an e-mail, using "nano-materials and nano-pigments that create an internal three-dimensional structure and dictate the polymer how to behave." Sure... We'll leave it to him to make any more 3-D-printed liquid metal-transferred art pieces.
Florea grew up in Romania, and the motivation behind picking the old Ford as his canvas came from his childhood memories of what an American car is - "big and wide and fascinating," he says - and the European name of the car itself, which it shares with an Italian city.