How the New Aluminum Ford F-150 Gets Built
Ford reinvented the bestselling vehicle in America by making the F-150 out of aluminum to cut weight. This is how you make a revolutionary truck.
Ford reinvented the bestselling vehicle in America by making the F-150 out of aluminum to cut weight. This is how you make a revolutionary truck.
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The new 2015 Ford F-150
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Rolls of high-grade aluminum that will go into the truck
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A crane operator at aluminum maker Alcoa's Davenport Works
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Alcoa's furnaces melt aluminum to be poured into molds that form giant ingots, bars that then go into the mill for rolling.
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Alcoa aluminum plant
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An ingot rolls into the hot mill
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Alcoa aluminum plant
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Alcoa aluminum plant
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Alcoa workers inspect the F-150's bed
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Aluminum rolls at Alcoa
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Scrap aluminium is 100 percent recycled
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Leaving Alcoa in a 2015 F-150, towing some of that aluminum
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Freshly stamped F-150 parts—door frames, fenders, hoods—wait to be sent to Ford's Dearborn Truck Plant
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F-150 parts headed to Ford's Dearborn Truck Plant
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The new truck has a 360-degree camera that's handy when you've got a 20-foot trailer
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The F-150's tow graphics show whether the truck is level
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Weighing in at a truck stop
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Stacks of aluminum parts
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Rolls of aluminum at Ford
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This is it: the lightest full-size truck body on Earth
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