BICYCLE PRODUCTION TOOLS

Carbon Preparation and Layup

Every rim begins with carbon fiber sheets cut to engineered patterns. Technicians place each layer by hand according to the rim’s layup schedule. Fiber direction and ply placement affect the rim’s strength, stiffness, and weight, so careful layup helps put material where it is needed without adding unnecessary bulk. This step creates the structural foundation of the rim before it ever enters the mold.

Molding and Curing

After layup, the carbon structure is placed into a custom-machined mold. The rim is cured under controlled temperature and pressure so the resin can set properly and the rim can take its final shape. Consistent molding helps reduce weak spots, shape variation, and hidden defects that could affect the finished wheel. The result is a rim structure designed to build predictably and perform consistently from one wheel to the next.

Drilling of spoke holes/drainage holes

This new generation of precision drilling machines is specifically designed for high-end wheel manufacturing, with drilling diameters ranging from 1.5 to 11 mm. The spindle angle can be adjusted bidirectionally within a range of -11° to +11°, enabling the effortless machining of vertical holes, angled holes, and chamfering of spoke holes. It also supports the drilling of drainage holes and the clamping of the full range of 20–32-inch wheels. With a repeat positioning accuracy of up to ±0.05 mm, it significantly improves wheel roundness and spoke lacing efficiency, replacing multiple processes with a single machine.

Cross-sectional inspection of cut pieces

Technical Description The rim cutting test (sectional inspection of cut pieces) involves analyzing the cross-sections of the rim by cutting a portion to evaluate internal and external features. This inspection focuses on identifying any burrs, irregularities, or deviations in dimensional specifications to ensure the rim meets our stringent quality standards.

Finishing and Painting

Each Light Travel rim is finished by experienced technicians. The rim is sanded, primed, painted, and labeled to create a smooth final surface and completed custom appearance. This process gives each wheel its final look while also helping technicians check surface quality before the rim leaves the factory. The result is a beautiful wheel, built custom for you.