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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.

NHTSA investigating 500k Ford and Mercury cars for lighting failures

The Ford Crown Victoria and Mercury Grand Marquis might be long gone as new models in showrooms, but the National Highway Traffic Safety Administration might check them out yet again for a potential problem. At the urging of North Carolina Consumers Council, the agency may open another investigation into the front lighting control module on vehicles from the 2003-2005 model years, and NHTSA estimates the issue could affect 517,945 vehicles. If the module stops working, it can cause a complete failure of all forward lighting, including the headlights. NHTSA previously investigated the issue in 2008 and 2009 but found no need for a recall, according to Bloomberg. Ford also extended the warranty on the part to 15 years or 250,000 miles. To prompt this new request, the North Carolina Consumers Council received a letter from a woman experiencing the module's failure. Upon further investigation, the council found 604 complaints of this problem on NHTSA's website, including seven crashes. Furthermore, the group has alleged that dealers told customers that the parts to perform the replacement weren't available, despite the extended warranty. According to the government agency, "A defect petition has been opened to evaluate the issue and make a grant or deny decision." Ford spokesperson Kelli Felker tells Autoblog via email, "We will cooperate with NHTSA, as we always do." You can read the council's complete letter to the Feds in PDF format, here. INVESTIGATION Subject : Loss of headlamp/exterior lighting Date Investigation Opened: APR 01, 2015 Date Investigation Closed: Open NHTSA Action Number: DP15002 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: The Office of Defects Investigation (ODI) has received a petition from the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The petition letter is attached for review. The petitioner alleges a defect in the lighting control module that powers the headlights which can result in the loss of vehicle headlights and/or all exterior lighting while driving. ODI has previously investigated this issue under PE08-066 which was closed without a defect finding.

FBI Seizes Computers, Listening Devices From Ford Headquarters

FBI agents searched Ford Motor Company's headquarters in Dearborn, Michigan, this month as part of an investigation into possible corporate espionage. Eight devices, along with documents, computers and financial records, were among the items seized by federal agents on July 11, according to documents obtained by The Detroit News. The FBI searched Leach's home on June 20 and seized more than two dozen items in that search, Reuters reported. Former engineer Sharon Leach, a 17-year Ford veteran of company, was fired last month, according to The News, which first reported the story. She admitted to placing recording devices under conference tables before meetings. She told Ford security she used the recordings to assist in her meeting notes. She couldn't remove the devices after meetings without drawing attention to herself, leaving the devices to record other meetings. Leach has not been charged for any wrongdoing. Former federal prosecutor and Wayne State University law professor Peter Henning told The News that using a search warrant, rather than a subpoena, shows the FBI suspects more employees could be implicated. "If it's an economic espionage case or trade-secrets case, that rarely involves one individual," Henning told The Detroit News. "So the concern is if you send a subpoena and ask for recording devices, those things can be erased." Leach, Ford and the FBI declined to comment on the investigation. Related Gallery AOL Autos Test Drive: 2014 Ford Fiesta ST Auto News Ford espionage corporate