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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.

How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

Junkyard Gem: 1991 Ford Festiva with 317K miles

Most cars that make it to astoundingly high mileage figures tend to fall into one of two categories: engineering masterpieces that ended up being hard to kill (and got a lifetime of at least the most important maintenance items) or machines that inspired unquestioning love from owners willing to keep opening their wallets for decades to keep them on the road. Today's Junkyard Gem falls into neither of those groups; it's a penny-pinching Ford Festiva, one of the cheapest cars available in its time … and yet it cracked the magical 300,000-mile mark before getting discarded. So, a total of 317,207.3 miles over its nearly 30 years on the road. We just saw a discarded 1989 Honda Civic with a mere 308,895 miles on the clock, and this Festiva comes close to topping this 1993 Honda Civic DX. The highest-mileage junkyard car I've ever found (keep in mind that most cars before the middle 1980s had 5-digit odometers, and most cars this century have unreadable-in-the-boneyard electronic odometers) is this 1987 Mercedes-Benz 190E with an amazing 601,173 miles. This Mercedes-Benz 300D came close, with 535,971 miles. Detroit went to six-digit odometers late in the game, but this 1986 Olds Calais reached 363,033 miles, and this Ford Crown Victoria Police Interceptor reached the 412,013-mile figure thanks to a second career as a taxi. A Festiva surpassing the 300k mark, though, is not something I ever expected to see. These cars were sold as cheap, no-frills transportation, period. The MSRP on a base-level Festiva started at $6,620 in 1991, or about $12,610 in 2020 bucks. Not many cars could squeeze under that price at that time; the Subaru Justy could be purchased for $5,995, the Hyundai Excel 3-door hatch cost $6,275, and the Yugo GV (yes, it could still be obtained new as late as 1991) had a hilarious $4,435 price tag. Even the lowly Geo Metro, Pontiac LeMans, and Toyota Tercel EZ cost more than this Festiva. Still, this car came with snazzy pinstripes, now faded to near-invisibility by the Colorado sun. You can see the cover plate in the spot where the air-conditioning button would have gone, had the original buyer of this car been willing to squander precious dollars on such frivolity. Five-speed manual transmission, naturally. You could get an automatic in the Festiva, but anyone willing to spend that kind of money on extras would have been able to afford a much nicer Tercel EZ.