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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 rakes in record $2.5b profit during Q1 of 2016

Fears that the auto industry is due for a downturn may be fading. Ford posted record profits in the first quarter of 2016, the company announced Thursday. Chief financial officer Bob Shanks said Ford enjoyed its best quarterly performance in history, generating operating profits of $3.8 billion and a record profit margin of 9.8 percent. Overall, the company's $2.5 billion profit in the quarter more than doubled from the 2015 quarterly results. "The first quarter was an absolutely terrific start to the year, an all-time record for the company, with very strong performance across the business," said chief executive officer Mark Fields. "We're excited about our future and confident in our ability to deliver long-term growth and profitability as we expand our business model to be both an auto and a mobility company." During the quarter, Ford announced the creation of Ford Smart Mobility, a new subsidiary that would vet future mobility projects in the realm of car-sharing, fractional ownership and autonomous deployment. The company also kicked off a billion-dollar makeover of its Dearborn, Michigan campus and headquarters. The company's after-tax earnings of $0.68 per share trumped Wall Street's expectations, and were significantly up from $0.39 per share a year ago. The results were buoyed by the company's fourth consecutive quarter of growth in Europe, which comes after a long period of stagnant sales. Ford's earnings results come amid reports that April car sales are on pace to jump 4 percent year over year, which would make it the best-selling April in history. Kelley Blue Book projects that car sales will reach 1.51 million this month, placing the industry on track for 17.5 million vehicles sold in 2016. Even as SUV and crossover sales drive the market, analysts say Nissan and Honda are positioned to benefit from renewed interest in mid-size cars. "Following a disappointing March, we expect sales to get back on track in April with SAAR in the mid-17 million range," said Tim Fleming, analyst for Kelley Blue Book. "Increased fleet sales and rising incentive spending among automakers remain the factors to watch, but the retail demand appears to be holding steady, signaling the industry's strong run isn't over quite yet." Related Video: Image Credit: Getty Earnings/Financials Ford Lincoln 5g Connectivity mobility auto industry financial

Ford recalls 90,736 vehicles due to engine valve issue

Ford will recall 90,736 vehicles as engine intake valves in the vehicles may break while driving, the National Highway Traffic Safety Administration (NHTSA) said on Saturday. The recall impacts certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine, the NHTSA said. According to documents posted by NHTSA and sourced from the automaker, "The engine intake valves may break while driving, which can result in engine failure and a loss of drive power." Following an investigation that started in January, 2022, Ford found 22 instances where "the engine intake valves fractured and fell into the combustion chamber of the engine causing catastrophic engine damage." The automaker's analysis continues: "Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after October 31, 2021." Fixing the problem will require replacement of the entire engine. "Dealers will inspect each vehicle to determine its cumulative number of engine cycles. For vehicles that do not meet the engine cycle threshold, dealers will accumulate high revolutions per minute (rpm) engine cycles per a service procedure. Engines will be replaced on vehicles that do not pass the engine cycle accumulation," Ford says.