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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 recalls Explorer, Flex, Taurus for parking brakes

Ford announced a recall of nearly 8,000 vehicles spread across a broad range of models for a faulty parking brake, which might not engage fully. The automaker has not received any reports of accidents or injuries resulting from the issue. The recall affects certain examples of the 2015-16 Ford Explorer, the 2015 Taurus, and the 2015 Flex. The 2015 Lincoln MKS and MKT are also included in the campaign. The vehicles in question were assembled at the company's Chicago and Oakville (Ontario) plants from May 4 to May 23. All told, 7,165 of the affected vehicles are estimated to be in the United States, with another 799 in Canada, and a solitary example in Mexico. In order to address the issue, owners are asked to bring the affected vehicles their local dealership, where technicians will inspect the vehicle and where necessary, replace the parking brake control assembly. Jul 22, 2015 | DEARBORN, Mich. Ford Issues Safety Compliance Recall in North America DEARBORN, Mich., July 22, 2015 – Ford is issuing a safety compliance recall for approximately 8,000 vehicles in North America, including certain 2015-2016 Ford Explorer, and certain 2015 Taurus and Flex, as well as Lincoln MKS and MKT vehicles for an issue with the parking brake. In these vehicles, the parking brake might not engage fully, which is a compliance issue with FMVSS 135 regarding brake systems. Ford is not aware of any accidents or injuries associated with this issue. Affected vehicles include certain 2015-2016 Ford Explorer vehicles built at Chicago Assembly Plant, May 4, 2015 through May 23, 2015; certain 2015 Ford Taurus vehicles built at Chicago Assembly Plant, May 4, 2015 through May 23, 2015; certain 2015 Ford Flex vehicles built at Oakville Assembly Plant, May 4, 2015 through May 23, 2015; certain 2015 Lincoln MKS vehicles built at Chicago Assembly Plant, May 4, 2015 through May 23, 2015; and certain Lincoln MKT vehicles built at Oakville Assembly Plant, May 4, 2015 through May 21, 2015. There are 7,165 vehicles in the United States and federalized territories, 799 in Canada and one in Mexico. Dealers will inspect the vehicle and, if necessary, replace the parking brake control assembly at no cost to the customer. Related Video: Featured Gallery 2016 Ford Explorer View 30 Photos News Source: Ford Recalls Ford Lincoln Crossover Sedan ford flex lincoln mks lincoln mkt

Poor headlights cause 40 cars to miss IIHS Top Safety Pick rating

Over the past few months, we've noticed a number of cars and SUVs that have come incredibly close to earning one of the IIHS's highest accolades, the Top Safety Pick rating. They have great crash test scores and solid automatic emergency braking and forward collision warning systems. What trips them up is headlights. That got us wondering, how many vehicles are there that are coming up short because they don't have headlights that meet the organization's criteria for an "Acceptable" or "Good" rating. This is a revision made after 2017, a year in which headlights weren't factored in for this specific award. This is also why why some vehicles, such as the Ford F-150, might have had the award last year, but have lost it for this year. We reached out to someone at IIHS to find out. He responded with the following car models. Depending on how you count, a whopping 40 models crash well enough to receive the rating, but don't get it because their headlights are either "Poor" or "Marginal." We say depending on how you count because the IIHS actual counts truck body styles differently, and the Infiniti Q70 is a special case. Apparently the version of the Q70 that has good headlights doesn't have adequate forward collision prevention technology. And the one that has good forward collision tech doesn't have good enough headlights. We've provided the entire list of vehicles below in alphabetical order. Interestingly, it seems the Volkswagen Group is having the most difficulty providing good headlights with its otherwise safe cars. It had the most models on the list at 9 split between Audi and Volkswagen. GM is next in line with 7 models. It is worth noting again that though these vehicles have subpar headlights and don't quite earn Top Safety Pick awards, that doesn't mean they're unsafe. They all score well enough in crash testing and forward collision prevention that they would get the coveted award if the lights were better.