Aluminum Shortage Still Squeezing Ford F-150 Output, Costs Set to Double by 2026
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The aluminum shortage that has dogged Ford’s F-150 production since late last year shows no signs of easing. According to The Wall Street Journal, Ford now projects it will spend $2 billion on commodities in 2026 — double its original estimate — driven largely by rising aluminum costs. The metal, essential for the lightweight body of America’s best-selling vehicle, remains in tight supply globally, with automakers competing for limited stock amid ongoing smelter closures and logistics bottlenecks.
“This isn’t just a Ford problem — it’s a structural supply issue that’s hitting the entire industry,” said Mark Chen, a supply chain analyst based in Detroit. “But because the F-150 is such a high-volume, high-margin vehicle, the impact on Ford’s bottom line is especially pronounced.”
Not everyone is sympathetic. “Ford had years to lock in better contracts and diversify suppliers,” said Linda Torres, a former procurement manager who now runs an automotive consultancy in Ohio. “Instead, they kept relying on the same few sources, and now they’re paying the price — literally. Two billion dollars? That’s not a shortage, that’s a failure of planning.”
The broader context is worrying. Aluminum prices have climbed steadily since 2024, driven by energy costs, trade restrictions, and reduced output from major producers in Europe and China. For automakers, the metal is irreplaceable in many EV and lightweight truck platforms, meaning the pain could persist well into 2027.
Elsewhere in the industry: Audi CFO Jürgen Rittersberger said on a recent earnings call that the company is “still evaluating a potential impact” of tariff increases on European auto exports by the Trump administration, “but it’s clear it would be a significant burden on our performance.” The luxury automaker is already planning to cut 7,500 jobs by 2029. [Automotive News]
Geely, Chery, and BYD all appear to be gearing up for Canadian market launches. Geely has been spotted deploying two SUVs from its sub-brand Jaecoo in Toronto in recent weeks, possibly for testing or exhibition. [Automotive News]
Volvo sold 10% fewer cars in the February-through-April period of 2026 compared to the same stretch in 2025. [Reuters]
Brembo is now in full production of a brake-by-wire system for an undisclosed automaker’s model line — suppliers aren’t always at liberty to name their customers. [Automotive News]
Volkswagen will field a Golf R with extreme aero, developed with Max Kruse Racing, at next year’s 24 Hours of Nürburgring to mark 25 years of the R brand, which began in 2002 with the Mk 4 Golf R32. [Volkswagen]
Red Bull has started series production of its 50 Adrian Newey-designed RB17 hypercars. Each one costs nearly $6.8 million. [Autocar]
BMW just built its 2 millionth battery electric vehicle — an i5 M60 — at its Dingolfing, Germany plant. [BMW]
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