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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.

Junkyard Gem: 1991 Mercury Capri

Ford has gotten a lot of use out of the Capri name in the United States. First, there was the Lincoln Capri in the 1950s, followed by the Ford Capri Mk1 (which was sold by Mercury dealers in the USA but never actually badged as a Mercury). Then came the 1979-1986 Mercury Capri, built on the very successful Fox Platform and essentially a clone of the Mustang. Finally, in 1991, the Australian Ford Capri came to the United States. Here is an example of this rare car that I spotted in a Northern California self-service yard not long ago. Mechanically speaking, the 1991-1994 Capri was a Mazda 323 under the skin, complete with a member of the same B-series engine family that went into such cars as the Miata and Ford Escort. So, for a few years in the early 1990s, car shoppers who wanted a sporty Mazda convertible could choose between a Miata and a Capri. The Capri had front-wheel-drive, but could be had with factory turbocharging. These cars were reliable and fun, but had a tough time competing with the Miata in the showroom battles. You'll see the occasional example now and then, but most of the 1991-1994 Capris have met the same fate that awaits this one. Related Video:

Recharge Wrap-up: Ford HQ gets giant solar array, Chevy City Express gets 24 MPG city

Ford will be building Michigan's largest solar array at its Dearborn headquarters. With funding from DTE Energy, the solar carport will provide covered parking, as well 30 charging stations for electric vehicles. The array is expected to generate 1.13 million kWh per year for Ford's operations, and offset 794 metric tons of carbon emissions. Read more in the press release below. Chevrolet announced the fuel economy for the 2015 City Express, at 25 mpg combined. The cargo van is rated at 24 mpg in the city, and 26 mpg on the highway. Chevy credits the van's inline four-cylinder engine and continuously variable transmission for its impressive city mileage. For its customers - which are mainly businesses - "The fuel economy of the City Express will help stretch their dollar at the pump and give them the flexibility to invest the savings back into their business," says Chevrolet's Ed Peper. The City Express starts at $22,950. Read more in the press release below. Engineers at the University of Wisconsin have developed an efficient engine that runs on a diesel-gas blend. The engine, which uses a computer to control the blend proportions, is about 15 percent more efficient than the any diesel engine according to mechanical engineering professor Rolf Reitz. The team has put the experimental reactivity controlled compression ignition (RCCI) engine in a demonstration car - a 2009 Saturn. "This vehicle can do 50 miles per gallon," says Reitz, who believes the system could be improved further. Read more at Wisconsin Public Radio. The Southeast Alternative Fuel Conference and Expo will take place in October in Raleigh, North Carolina. Held at the NC Clean Energy Technology Center from October 22-24, the event will feature a variety of exhibitors, speakers and, most importantly, alternatively powered vehicles. "The three day conference will be a one-stop shop for fleet and transportation related decision makers to learn about return on investment, efficiency and alternative transportation fuels such as biodiesel, electricity, ethanol, propane and natural gas," says Anne Tazewell of the NC Clean Energy Technology Center. If you can't make it to Raleigh for the Expo, you can still enter to win a free two-year lease of a Nissan Leaf at the Center's website. Learn more about the event in the press release, below.