Does Ford still use an aluminum body?
Yes. Ford continues to use aluminum body panels on several vehicles, most notably the F-Series pickups, as part of its ongoing light-weighting strategy. The aluminum panels are paired with a steel frame to achieve weight savings while maintaining strength.
The following report explains Ford’s current approach to aluminum in its vehicle bodies, which models use aluminum today, and what that means for owners and service providers.
Ford's aluminum strategy today
Ford began using aluminum body panels on the F-150 in 2015 as part of a broader effort to reduce vehicle weight and improve efficiency. Since then, the company has largely kept an aluminum-body approach for its light-duty trucks, while applying a mix of materials across the rest of the lineup. This strategy continues to influence design decisions, manufacturing processes, and repair considerations for Ford owners.
In practice, the most visible application remains the F-Series, where the exterior panels are predominantly aluminum, while the frame remains steel. Other models incorporate aluminum components where it makes sense for performance, efficiency, and durability, rather than adopting a full aluminum body across the board.
Where aluminum shows up in Ford's lineup
Below are the model areas Ford has highlighted for aluminum body panels or aluminum-intensive construction in recent years. The list focuses on mainstream, mass-market vehicles rather than niche trims.
- Ford F-150 and related light‑duty trucks: Aluminum outer panels (hood, doors, fenders, and tailgate/bed skin) combined with a high-strength steel frame to save weight and boost efficiency.
- Ford F-150 Lightning: The electric variant uses the same aluminum body panel approach as the gasoline-powered F-150 family, reinforcing the weight-saving strategy for electric propulsion.
In short, Ford's aluminum-body strategy remains centered on the F-Series, with other models using aluminum components where appropriate rather than pursuing a fully aluminum lineup.
Practical implications for owners and service
Aluminum body panels require different repair and maintenance approaches compared with traditional steel bodies. Repair shops need specialized equipment, training, and procedures to handle aluminum-to-steel joints, bonding, and corrosion protection. For buyers, the aluminum design can contribute to better fuel economy and payload efficiency, but it can also affect repair costs and availability of replacement parts in some markets.
Summary
Ford continues to employ an aluminum body strategy, most prominently in the F-Series pickups (including the F-150 and its electric variant, the F-150 Lightning). The company uses aluminum components in other models as part of a broader mixed-material approach, rather than a wholesale shift to aluminum across its entire lineup. This approach aims to balance weight reduction, performance, durability, and repair considerations for owners.
