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2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.

Ford sets world record for biggest Hot Wheels track loop

Take Your Child to Work Day looks like a pretty amazing experience for a child if their parent works at Ford. For the recent event, workers at the Blue Oval set up the world's largest Hot Wheels track loop in the atrium of the company's Research and Innovation Center in Dearborn, MI, and launched toy cars from over three stories. The idea came from Ford dynamometer technician Matt West who had been building progressively larger loops with his son. This one was the biggest ever, though, with a ramp 35.5-feet high and a 12.5-foot loop to crush the previous record of nine feet, nine inches tall. Fittingly, the track was inaugurated with a Ford Mustang Hot Wheels car taking the first run. To support such a massive size, the Hot Wheels track fits into a plywood structure that's bolted together. Beyond just being fun and looking incredibly cool, the stunt was meant to teach kids about mathematics and engineering. Ford Sets World Record for Biggest Hot Wheels Car Track Loop in Support of Take Your Child to Work Day • To help children cultivate an interest in science and engineering, Ford attempted to set a new world record for building the largest Hot Wheels® car track loop as part of this year's Take Your Child to Work Day • Ford Mustang Hot Wheels car started at more than three stories high inside Ford Research and Innovation Center • Old record loop stood at nine feet, nine inches tall DEARBORN, Mich., April 23, 2015 – Ford ran circles around the old Hot Wheels® record loop as part of this year's Take Your Child to Work Day. When the effort was complete, Ford had made a world record attempt with a Hot Wheels car track loop that exceeded 12 feet tall. The world record attempt was the brainchild of Ford dynamometer technician Matt West, who had built increasingly large Hot Wheels loops with his six-year-old son Blade at their home in Monroe, Michigan. The attempt took place in the three-story atrium of the company's Research and Innovation Center in Dearborn in support of Ford's participation in national Take Your Child to Work Day. "It started as part-fun, part-physics lesson with my son at home," said West. "We built one in our playroom, and then built a five-foot- tall loop in our backyard.

Shelby GT350R offers first mass-produced carbon fiber wheels

In the world of race engineering, reducing total weight is good, but reducing unsprung weight is flippin' fantastic. That's the reason Ford is pushing the envelope in terms of technology for the Shelby GT350R's wheels. Joining the likes of Koenigsegg in the offering, Ford has teamed with Australian outfit Carbon Revolution to produce the CF rollers en masse for the first time. Destined for the hubs of the new Shelby GT350R, the new hoops weigh just 18 pounds each, versus the 33-lbs weight of a similar aluminum wheel. On top of slashing up to 60 pounds in unsprung weight, there's such a reduction in rotational inertia – 40 percent, versus aluminum wheels – that Ford actually has to recalibrate the magnetic ride control system and springs. Thanks to, we're guessing, scenes of crashed Formula One cars disintegrating and spewing shards of carbon fiber all over the track, Ford seems quite keen to do away with the idea that CF is strong, but brittle. The company conducted extensive shock testing, ramming a wheel into a curb at speed. According to the Blue Oval, the lightweight wheel allowed the suspension to respond so quickly that the impact was "greatly diminished," causing the tester to run the experiment again, thinking there'd been a mistake. After recording brake rotor temperatures of 900 degrees Celsius (over 1,650 degrees Fahrenheit, or well past the point that aluminum or magnesium would melt) during testing, Ford and Carbon Revolution actually redesigned the wheels to "a thermal standard more suitable for motorsports," by adding an "incredibly thin, nearly diamond-hard coating that reliably shields the resin from heat." The same process was used to protect engine turbine blades on the Space Shuttle. While the work by Ford and Carbon Revolution should make GT350R customers excited, the work being done here could have serious implications for performance cars in the future. That's the real takeaway here, and is something that should leave fans of all performance vehicles excited.