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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.

2016 Ford F-150 gets propane, CNG conversions

It's a complete mystery if a hybrid Ford F-150 will ever see showrooms, but for buyers looking for an alternative fueling method, Ford has an option ready. For the 2016 model year, the Blue Oval is offering a kit that converts the pickup's 5.0-liter V8 to run on compressed natural gas or propane. The package costs $315 and adds improved valves and valve seats to work with the gaseous fuels. From there, the F-150s go to an upfitter to install the actual fuel tanks, lines, and injectors. Ford estimates this costs $7,500 to $9,500, depending on how much CNG a buyer wants to carry. After the conversion, the tow rating remains the same as running on gasoline, and payload is only reduced by the weight of the system. Ford offered a CNG option on the last-gen F-150's 3.7-liter V6, and sales beat the automaker's forecasts. With the greater grunt available from the V8, the company is expecting the conversion to be even more popular on the new pickups. In times of high fuel prices, CNG models have been a way for fleets to reduce their costs. According to Ford, the average price of natural gas nationwide is $2.11, but it's as low as $1 in some areas. The US Energy Information Administration lists the average for regular gas at $2.57 and diesel at $2.81. Chevrolet and GMC also offer a CNG conversion option on some of their heavy-duty trucks, and Ram does, as well. 2016 F-150 WITH CLASS-EXCLUSIVE COMPRESSED NATURAL GAS, PROPANE CAPABILITY GROWS FORD'S ALTERNATIVE FUEL LEADERSHIP Responding to customer requests, 2016 Ford F-150 with the 5.0-liter V8 engine will offer a gaseous-fuel prep option, making it the only light-duty pickup capable of running on compressed natural gas or propane Ford has sold more than 57,000 vehicles prepped to run on clean, low-cost compressed natural gas and propane – seven times more than all other major U.S. automakers combined – since 2009 Ford has the broadest portfolio of natural gas and propane offerings, including 2016 F-150 and Super Duty trucks, and Transit and Transit Connect vans and wagons Ford Qualified Vehicle Modifiers offer a wide variety of CNG options to help customers find the best, most cost-effective solution to their diverse operating needs Ford, America's truck leader, will offer the 2016 F-150 with an available gaseous-fuel prep package that enables 5.0-liter V8-powered models to run on clean, low-cost compressed natural gas or propane, making Ford the only manufacturer of a CNG/propane-capable half-ton pickup.

The tricky business of octane, power, and MPG

Given tepid green-car sales numbers this year, consumers in the US aren't making the transition away from internal combustion engines too quickly. Regulations are still mandating cleaner emissions, though. In addition to downsizing and turbocharging, there's growing consideration about moving to higher-octane fuel to improve overall efficiency. In a new report, engineers at FCA, Ford and General Motors Powertrain are showing that it could work, too. The major advantage to higher-octane fuel is that it supports higher compression ratios. That in turn can lead to more power from burning the same amount of gas. "Higher ethanol content is one available option for increasing the octane ratings of gasoline and would provide additional engine efficiency benefits for part and full load operation," the researchers write in the study's abstract. The authors even think it could be possible to update some modern vehicles' engine calibration to be optimized for the better gas. While the benefits are there, we still have a long way to go before higher-octane fuel becomes a national standard. According to Green Car Congress, 87 percent of the gas sold in the US is regular grade 87-octane. Meanwhile, premium 91-93 octane makes up just 10 percent. The various grades of fuel illuminate even more annoyances with the current system. For example, Ford generally recommends 93-octane for EcoBoost engines, and the power outputs that the company publishes are based on using it. However according to Green Car Reports, such premium gas is very difficult to find in some regions of the US, especially along the West Coast. The powertrains still run on lesser grades but with lower power output. The researchers' discussion of possibly increasing ethanol in gas also comes during a heated debate on the substance. The current administration is pushing for less of the corn-based fuel in the coming years. Although, several presidential hopefuls might be favor of reversing that course.