Process

OUR APPROACH

From visualizing the initial concept to the final production of the wheel, we’ll be there every step of the way to help you design your wheels from scratch, to the exact requirements you need and want.

CAD Modeling

We use parametric CAD software to design our wheels, allowing precision modelling to be within 0.01mm, and for us to easily assess and modify features against the design intent and the predicted outcome throughout the process. Every design will pass through multiple drafts until the look is perfect.

Design Optimization

When the core design is ﬁnalized, our designer begins enhancing the performance and look. Each set of wheels is designed with speciﬁc weight reduction strategies in mind, such as spoke hollowing and weight reduction pocketing. Concavity or dish depth is optimized as per client’s request. Brake clearance will also be verified to make sure mounting the wheels will be hassle-free.

Finite Element Analysis

Before going into production, the designer will perform computer simulation tests – Finite Element Analysis – to make sure all applicable JLW, VIA and TUV safety standards are met. The highly predictable mechanical properties of forged 6061-T6 aluminum alloy allow us to pinpoint potential stress points in the wheel and predict its performance with FEA to an exceptional degree of accuracy.

THE FORGED DIFFERENCE

CAST WHEELS

Typical OEM (and most aftermarket) wheels, made by pouring molten aluminum into a mould. Casting is inexpensive and allows for mass production of low-cost alloy wheels. However this method creates very porous metal - air pockets inside the metal reduce it’s structural integrity. Not only are cast wheels weaker, but in order to compensate for the weaker metal they must be reinforced with thicker spokes and extra material, making them heavier as well. In addition, added mass to the wheel also greatly reduce handling of the vehicle and feedbacks from the road surface.

FORGED WHEEL

Machine-forged wheels are made from a single forged aluminum block. It is subjected to immense heat and pressure, changing the very properties of the metal - compressing it, eliminating air pockets, aligning grain structure and improving uniformity. It is then shaped through multiple steps of precision CNC machining into the selected design. The resulting wheels are signiﬁcantly stronger than cast wheels, lighter than rotary forged wheels, and far more capable of handling a spirited driving style and track use. Since every set of wheels are made to order, the customization possibilities on them are endless.

FLOW FORMED WHEELS

Also known as rotary forged, flow formed wheels begin their lives as cast wheels, speciﬁcally cast with a shortened barrel. The barrel is pressed against a heated hydraulic roller and spun, compressing and stretching it, decreasing the porosity and improving the quality of the metal. While they weigh less than cast wheels and have similar strength to forged wheels in barrel, ﬂow formed wheels cannot quite match the strength-to-weight ratio (and resulting freedom in design choices) of machine-forged wheels.

OUR MANUFACTURER

We have vetted numerous manufacturers across North America and Asia in order to partner with one that can meet our strict product standards. Our eventual goal is to bring wheels manufacturing to Vancouver and gain complete control over production from the start to the final packaging. We appreciate everyone’s support on this journey to become the very best Canadian aftermarket wheel manufacturer.

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Figure 1. High-speed vertical milling centre array.

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Figure 2. After milling is complete, the artisan hand-cleans the wheel surface to prepare the wheel for finishing.

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Figure 3. Centre-piece of multi-piece modular wheel – milling of the weight reduction pockets was completed.

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Figure 4. Forgings after the initial lathe process. Next, the spoke details will be milled out.

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Figure 5. A lathed forging next to a freshly milled out wheel.

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Figure 6. Forgings set up in the CNC milling centre, waiting to be processed.

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Figure 7. Freshly milled out wheel inside the vertical milling centre.

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Figure 8. A well-stocked forging storage area.

GET IN TOUCH & Get A FREE QUOTE

Ready to make your own set of wheels? Send us a message about your Bespoke Forged Project idea for a free quote, and to discuss your idea – we love hearing them! Fields marked with an asterisk (*) are required.