Every carbon rim begins as a carefully engineered laminate structure.

Before physical production starts, the rim profile, fibre orientation and material distribution are developed through our Augmented Validation Process (AVP). Computational analysis allows us to evaluate how the structure is likely to respond to the forces generated during riding, cornering, braking, tyre inflation and impact loading.

The objective is not simply to create a rim that is lightweight. The structure must remain balanced, stable and dimensionally consistent throughout its intended operating range.

Engineering the Laminate

Carbon fibre performs differently depending on the type of fibre used, its orientation and its position within the laminate.

During the design phase, we plan the placement of each material to provide strength and stiffness precisely where they are required. Typical riding loads and tyre pressures are modelled first, before the structure is assessed against forces and pressures considerably beyond those expected during normal use.

This helps us understand how the rim responds not only within its intended use case, but also when pushed well beyond it.

High-modulus fibres play an important role within our latest rim structures. Their mechanical properties allow us to achieve a highly efficient balance of stiffness, responsiveness and low weight. However, these materials are also more demanding to work with.

They require greater precision during cutting, placement and consolidation. Small variations that may be less significant with conventional materials can become increasingly important when working with higher-modulus fibres and highly optimised laminate schedules.

As a result, these layups take more time, greater control and a higher level of manufacturing skill.

Combining Analysis With Physical Testing

Computational analysis provides an essential foundation, but it does not replace physical testing.

Prototype rims are subjected to repeated laboratory evaluation using parameters representative of real-world riding. Loads are then increased beyond those normally encountered to examine how the structure behaves with a significant margin above its design intent.

The results of this testing are fed back into the development process. Fibre orientation, material transitions and individual reinforcement areas can then be adjusted before further prototypes are manufactured and tested.

This iterative process is completed in close collaboration with our highly skilled composite operators. Their practical experience is essential when translating a theoretical laminate design into a repeatable production process.

The final structure is therefore not developed through software or physical testing alone. It is refined through a combination of computational analysis, prototype validation, manufacturing experience and continuous feedback.

Testing Rim Flatness Under Tyre Pressure

The footage shown here captures one of the quality-control procedures carried out during production.  Rims are selected from manufacturing batches and measured for flatness in their uninflated state. A tyre is then fitted and the pressure is increased gradually, progressing beyond the rim’s intended operating conditions.

The tyre is subsequently deflated and the rim is measured again. This process is repeated multiple times.

The purpose of the test is to confirm that the laminate remains balanced as tyre pressure applies a continuous load around the rim. Following repeated inflation cycles, the rim should retain its intended geometry without developing distortion or a measurable change in flatness.

This provides an additional verification of the laminate design, fibre placement and manufacturing consistency.

Verified Before Building Begins

Flatness testing is only one of the many inspections and controls carried out before a rim is approved for wheel production.  Each stage exists to ensure that the finished component remains consistent with its original design intent. Only after these checks are completed are the rims released, shipped to Belfast and built by hand by our expert wheel technicians.

Performance begins with design, but it is delivered through control, repeatability and attention to detail at every stage of the process.