Research and Development
Cutting edge-design and manufacturing methods developed in the automotive and aerospace industries are used to make FRX5 wheels.
The FRX5 is one of the most advanced one-piece composite wheels available today. The one-piece wheel design is covered under worldwide patents.
Unlike other composite wheels we do not bond a rim or recut the molded bead into our wheels. Our wheels are truly "One-Piece".
The "Lost Core Molding Process" we use to manufacture our wheels also enables us to design complex geometries with varying wall sections thru-out the wheel. We produce uniquely shaped wheels with optimal structural properties.
3D-Design and Modeling
- Solid Works software is used to design the wheel and corresponding mold
- This software enables the designer to thoroughly design and analyze every detail of the wheel and mold in three dimensions
- The design data is then used to create virtual prototypes including complete wheel assemblies
FEA (Finite Element Analysis)
- This method of analysis allows the simulation of forces acting on the wheel. We are then able to establish the load and deflection characteristics of the wheel.
Rapid Prototyping
- A solid prototype is constructed to confirm physical dimensions and interface the wheel with the bike frame and drive components
Composite Materials
- We use the most advanced, high impact, glass reinforced composite materials available today
- The composite material provides the optimal balance between impact, flexure and density properties
Load Testing
- Laboratory load testing is performed to confirm FEA analysis and establish maximum loading limits
Dimensional Measurements
- High precision measuring equipment is used to confirm part dimensions prior to final manufacturing of the wheel mold
Field Testing
- Rigorous true life testing by pro rider Yanni Antonakos
Manufacturing Technology
Our unique hollow formed wheels are made using a proven manufacturing technology called "Lost Core Molding".
The manufacturing process starts with molding a low-melt point metal mandrel. This mandrel is then over molded with a composite thermoplastic. The mandrel or "core" is then melted out leaving behind the hollow-formed composite wheel.
This technology allows us to design complex geometries with varying wall sections thru-out the wheel. We produce uniquely shaped wheels with optimal structural properties.
One of the most technically advanced "lost core molding work cell" available today is used to manufacture our wheels. This equipment repeatability ensures part to part manufacturing consistency. The "lost core molding equipment" is covered under worldwide patents.