Starting from the style provided by the car manufacturer, we optimized the design of the rim for the subsequent CNC machining, starting from a forged blank. We performed several FEA calculation cycles to simulate all the approval tests required by the car manufacturer, with the aim of reducing to a minimum the final weight of the object.

The end result was provided in the form of complete and ready to production 3D models, as well as 2D drawings for the production and in-line quality control.

This project had been provided by the customer almost ready for production. The request was to use FEA simulations to analyze the behavior of the wheel subjected to fatigue tests – such as rotating bending and rim rolling – required by the road regulations of the German TÜV.

We identified the weak points of the rim, changed the style in order to eliminate the problems and finally removed the material where not required.

In this way, the customer saved time and money by avoiding to produce a model that would have later failed the test.

The motorcycle wheel design – to be produced in fusion with low pressure – had been provided by the customer almost ready for production. We were asked to use the FEA simulations to analyze the behavior of the wheel subjected to road use.

We identified the weak points of the wheel, changed the style in order to eliminate the problems and finally removed the material where not required. In this way, the customer saved time and money by avoiding to produce a model that would have later failed the tests, with the resulting changes in production equipment and subsequent new casting processes.

Over the years we have realized different projects in the field of sports bike: stems, appendices for time trial handlebars, saddle fixing and cranks.

The studies have included a part of design and engineering development, defining the style or starting from a base provided by the customer, with the technical specifications and project requirements defined and discussed together with the customer’s technical department.

We have carried out FEA / FEM analysis by simulating different kinds of use and performed the laboratory tests for the internal approval or in accordance with the various regulations TUV and DIN, ISO and UNI.

Particularly sensitive to cutting (shearing effect), the carbon tube of the saddle support has been analyzed in detail to eliminate any critical point.

The Customer asked to produce a full range of aftermarket wheels, with a unique style, declined in different sizes.

We developed the style, starting from the customer needs, optimizing it with FEA / FEM calculation for the first size, developing all the applications required for different cars.

After the customer’s approval, we developed the other sizes of the wheels, without modifying the original style.

The rim had been requested with both front and rear configuration, and would replicate the style of a forged wheel already produced by the manufacturer in order to be used on a motorcycle model of a lower segment. The production was commissioned from a company in the Far East and required the gravity casting in a sand-based steel mold, which was necessary given the hollow shape of the hub.

The 2D drawings we made were fundamental for the production and quality control management allowing the Customer to interface with the remote production company on a clear and defined common basis.

The aim of this project was to provide a major manufacturer of wheels with a new line of rims that could adapt to different cars. The customer requested specifically a sporty-looking wheel with a touch of European style.

The production process started from forged raw material and had to include different style proposals and finishes. We provided 3D rendering of the various wheel models and FEA calculations for the most interesting versions. Finally, we developed a complete series of photomontages using different sports cars to check the final effect.