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How Ford's light lab keeps the sun shining on the new Mustang just right [w/video]

Anyone who's bought one of those old school metal shift knobs knows they're really cool until they sit in a parking lot in the sun for a few hours. Then they're not cool at all. Likewise, features such as the aluminum dash on the 2015 Ford Mustang can be all kinds of neat right up until the sun hits it just the right way and sends shards of blinding light through the cabin. The Ford Visual Performance and Evaluation Lab is where engineers figure out how to make sure that doesn't happen.
Cars like said Mustang are parked inside the 30-foot reflecting dome under 6,000 watts of lights that can mimic the sun at any time of day and in any weather condition. Engineers can then spend cold, overcast days inside, testing for interior legibility, glare and reflections on every interior and exterior surface as if it were bright and sunny. They can also learn how a car's sheetmetal and colors will look out of doors, all year round.
Ford showed off the lighting lab without the music and interviews three years ago when the Explorer was being prepared. You can watch it at work again in the video below, and read about it in the press release below that.

Ford doubling 1.0L EcoBoost engine production

Ford's 1.0-liter EcoBoost three-cylinder engine hasn't been around that long, but it sounds like the engine is getting to be fairly popular in the automaker's global car lineup. The Detroit News is reporting that Ford has add a second shift that will allow its German engine plant to double daily output from 500 engines to 1,000.
The increased capacity is part of a plan to sell more than 300,000 vehicles a year with this engine in Europe by 2015. Europe is currently the only market where the smallest of the EcoBoost engines is offered (including in the Focus pictured above), but US-spec Fiesta models will be getting this mill for 2014.
Three-cylinder engines are expected to continue to grow in popularity in coming years with the report indicating that global production of these engines will double by 2018 to 9.8 million units. General Motors, BMW and Mitsubishi are all expected to introduce three-cylinder engines in the near term, as well.

IIHS updates overlap test: 2 SUVs get good marks, 9 fare poorly

Vehicles in crashes keep occupants safe by deforming around the cabin in a way that maintains cabin integrity. The Insurance Institute for Highway Safety's moderate overlap test, introduced in 1995, has been a huge contributor to improved safety for front-row passengers in a crash. IIHS President David Harkey said, "Thanks to automakers’ improvements, drivers in most vehicles are nearly 50% less likely to be killed in a frontal crash today than they were 25 years ago." In the 'unintentional side effects' column, crash safety has gotten worse for passengers in the back seats. When carmakers reengineered the front crash structure to protect the driver, more crash forces got distributed throughout the rear. IIHS research claims rear passengers have a 46% greater risk of fatal injury than front-row passengers, but back-seaters haven't benefited from the same upgrades in safety as the front row. The IIHS updated its moderate overlap test to address the issue, putting 15 vehicles through the new regime. Two earned good ratings — the 2023 Ford Escape and the 2021-2023 Volvo XC40 — one was acceptable, three were marginal and nine were rated poor. Every one of the crossovers sampled got good marks for all passengers in the original test. That test sees 40% of vehicle's width on the driver's side impacting an aluminum honeycomb barrier at 40 miles per hour. The updated test puts a crash dummy representing small woman or 12-year-old child in the seat behind the driver, the dummy's sensors and grease paint measuring the effectiveness of the restraints and the forces a human body would need to endure. To achieve a good rating, the "measurements must not exceed limits indicating excessive risk of injury to the head, neck, chest, abdomen or thigh." An institute engineer said, "In real-world crashes, chest injuries are the most common serious rear-seat injuries for adults." The sensors and video evidence showed back seat dummies in the Escape and XC40 endured minimal risk of injuries from excessive crash forces, from submarining under the seat belt, or from unwanted interaction with the side curtain airbag.   The Toyota RAV4 scored acceptable. The second-row dummy also endured minimal risk of injury to the chest and lower extremities. However, the lap belt slipped upward in a way that could increase abdominal injuries, and after the dummy's head dipped during crash impact, the head came back up between the rear curtain airbag and rear window.