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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Ford bringing production F-150 to Detroit with Atlas styling and Alcoa blast shields

According to a report in Bloomberg, the 2015 Ford F-150 will indeed be showing up at the Detroit Auto Show next month. It will bring attitude with it, not only in the form of sheetmetal inspired by the Atlas concept (pictured) that appeared at the 2013 Detroit show but also in the Alcoa military blast shields among the display being used to showcase the ruggedness of aluminum.
There's been a lot of talk about the F-150 switching to aluminum body panels (although maintaining a steel frame), and for good reason. The lightweight body is expected to shed more than 700 pounds and greatly increase its highway mileage, but production-line issues and possible delays have been a major focus of attention concerning the best-selling vehicle in America for 32 years, meaning Ford has to get it right. F-150 is responsible for a massive portion of the company's global profits and it will come in a year when company profits are already predicted to decline because of new car launches.
When it comes to dings, the Bloomberg story says Ford wants Alcoa to supply some of the military-grade aluminum it uses for blast shields on battlefield vehicles to help it talk up the toughness of aluminum. Reading commentary on the many stories about the F-150 reveals there are many more little questions about the aluminum overhaul, like "How much will it cost to repair and insure?" and "How will companies hang their magnetic signs?" Answers should start coming in a couple of weeks.

North American Car, Truck and SUV of the Year finalists revealed

The finalists for the 2023 North American Car, Truck and Utility Vehicle of the Year Awards were announced Thursday at the L.A. Auto Show. — The Acura Integra, Genesis Electrified G80 and Nissan Z made the cut in the car category. — The Ford F-150 Lightning, Chevy Silverado ZR2 and Lordstown Endurance advanced in trucks. — And the Cadillac Lyriq, Genesis GV60 and Kia EV6 advanced among utilities.  The winners will be announced Jan. 11 in Detroit.  The finalists underscored the industryÂ’s shift to electric vehicles, as all three utilities and two of the three trucks are EVs. The finalists were culled from a list of 26 semifinalists made up of three trucks, 10 cars and 16 utility vehicles that are new this year.  Notables that missed the cut include the Mercedes EQE, Subaru WRX and Toyota GR Corolla in cars; while the Honda CR-V, Kia Sportage and Rivian R1S were among the utes that did not advance. The three trucks are the only ones eligible this year and have advanced through the voting.  50 jurors who work for media outlets across North America vote three times over the course of the year to whittle down the field, which was originally 47 vehicles. Jurors also test the semifinalists at an October group event in Ann Arbor, Mich. The Honda Civic (car), Ford Maverick (truck) and Ford Bronco (utility vehicle) were the 2022 winners. Autoblog Editor-in-Chief Greg Migliore is a NACTOY juror.   Featured Gallery Ford F-150 Lightning View 48 Photos Green LA Auto Show Acura Cadillac Chevrolet Ford Genesis Kia Nissan Truck SUV NACTOY Lordstown Endurance