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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 rolls out diesel Focus ST at Goodwood [w/poll]

If you're in the market for a hot hatch, there are some excellent choices at your disposal - especially if you live in Europe. But if you want a diesel, well, your choices become rather more limited. Volkswagen tends to that niche market with the Golf GTD (essentially an oil-burning version of the GTI available Stateside), but that's about the extent of it. The pleas of those looking for more diesel-burning hot hatch choices haven't fallen on deaf ears at Ford, with the Blue Oval not only rolling out a facelifted gas-powered Focus ST at the Goodwood Festival of Speed this weekend, but also a new diesel version as well.
The diesel Focus ST (which we hope and pray isn't marketed as the STD) packs a 2.0-liter turbodiesel four producing 182 horsepower and 295 pound-feet of torque to propel the oil-burning hot hatch to 62 in 8.1 seconds en route to a top speed of 135 miles per hour. With less power and only slightly more torque, that makes the diesel Focus ST considerably slower than the gasoline one, which packs 252 hp and 270 lb-ft, runs to 62 in 6.5 seconds and tops out at 154 mph, but (in a testament to how far particulate filters have come) the diesel model cuts carbon emissions by nearly a third compared to the petrol version and returns about 50-percent better fuel economy, which makes that much more of a difference in markets where diesel is already priced better than gasoline at the pump.
For buyers who wouldn't consider anything other than a diesel, it also represents 23-percent more power than the previous top-level diesel Focus. The VW Golf GTD, for reference, offers up 181 hp (just 1 horse less), 280 lb-ft (15 fewer torques) but is somehow estimated to reach 60 in a considerably fleeter 7.4 seconds.

Feds open investigation into Chevy Express, Ford Freestar rust issues

'Tis the season... for road salt. And with that, comes rust. And what does rust bring? Well, for Ford and General Motors, a National Highway Traffic Safety Administration investigation. According to The Detroit News, NHTSA is looking into potential recalls issues with Chevrolet Express vans and Ford Freestar minivans.
The feds have received five complaints that rust has caused leaking fuel filler pipes on 2003 Express vans. Separately, seven complaints have been filed over excessive rust in the rear wheel wells of 2004 Ford Freestar and Mercury Monterey minivans. The Freestar and Monterey went out of production in 2007. Neither issue has resulted in any crashes or injuries, according to the report.