For fleet managers, the growing cost of aluminum and other raw materials could soon make replacing and maintaining vehicles even more expensive. Ford’s aluminum-bodied F-150, long praised for reducing weight and improving fuel economy, is now facing a different problem: soaring aluminum prices. Costs have climbed sharply over the past year due to tariffs, supply shortages, and conflict in the Middle East, especially after the closure of the Strait of Hormuz disrupted global shipping routes. Ford expects billions of dollars in additional material expenses, and other major automakers are dealing with similar increases in the cost of steel, copper, and plastics.

These rising expenses are expected to push vehicle prices even higher at a time when many fleets are already struggling with tight budgets and delayed replacement cycles. While aluminum still offers benefits like better fuel efficiency and corrosion resistance, automakers are unlikely to move back to steel because retooling factories would be too costly. Instead, manufacturers will likely continue raising prices and cutting costs elsewhere, including reducing physical controls and expanding subscription-based vehicle features. For fleets, this could mean higher acquisition costs, more pressure to extend vehicle lifecycles, and growing concerns about long-term operating expenses as the industry continues facing supply chain and affordability challenges.