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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.

Man has surgery to remove T-Bird turn signal that's been in his arm for 51 years

In 1963, real estate agent Arthur Lampitt was driving a new Ford Thunderbird near East Peoria, Illinois on his way to an appointment when he collided head-on with a truck. A massive accident that was so bad that it was originally reported as a fatal crash, Lampitt suffered a broken hip and that became the focus of doctors' efforts. In fact, no one noticed the fact that the turn-signal stalk had been broken off the steering column and had lodged itself in Lampitt's arm. Fast-forward to around ten years ago, when Lampitt set off a courthouse metal detector because of a "slender object, about the size of a pencil" in his arm. Despite that unnerving discovery, the doctor who examined Lampitt said that since it didn't hurt, he needn't worry about it. This year, however, it did start hurting and the affected arm started to bulge. Lampitt decided to have the issue seen to, and suspected it might have something to do with his 1963 accident. When he looked through photos of the wreck taken by a friend, he noticed the turn-signal stalk of the Thunderbird missing and figured that was the culprit. After a 45-minute outpatient surgery, the surgeon verified it: a slim, slightly bent and corroded, seven-inch metal cylinder with a trumpeted end. The surgeon said a protective pocket had formed around it, which is why it could remain in Lampitt's arm so long, but it was still unusual - "We see all kinds of foreign objects like nails or pellets, but usually not this large." Lampitt, who is expected to make a full recovery, says he might make a keychain out of it, once he's done just holding it. News Source: St. Louis Post-DispatchImage Credit: Jesse Bogan, St. Louis Post-DispatchTip: Jon Auto News Ford Coupe accident wreck ford thunderbird turn signal

Next Ford F-150 delayed for aluminum body panel issues?

The timetable for next-generation Ford F-150 may be in trouble if a report from The Truth About Cars is true. The next F-150 is slated to make extensive use of weight-saving aluminum in its body, but the aluminum alloy provided by suppliers hasn't met Ford's requirements in the earliest phases of pre-production, according to the report.
The F-150 represents a huge portion of Ford's profits and is the best-selling truck in the US, even in the face of increased pressure from cross-town rivals General Motors and Ram. While the current truck is treading water against its competition, we'd be lying if we said the F-150 weren't growing quite long in the tooth.
If production of the next-generation of the Ford cash cow, said to be based on the Atlas Concept from the 2013 Detroit Auto Show (pictured above), is delayed, it could be bad for Ford. Production at Ford's Dearborn Truck Plant is already set to be delayed six to ten weeks, missing an internal on-sale deadline of Memorial Day.