Carbon Preparation and Layup

Every rim begins its life as rolls of high-grade carbon fiber sheet, precision-cut by CNC-controlled machines into thousands of engineered patterns. Each ply is cut to exact dimensions and orientation, with fiber angles meticulously calibrated to match the rim’s structural requirements.

From there, skilled technicians take over. Following a detailed layup schedule developed through extensive finite element analysis and real-world testing, they place each carbon fiber layer by hand onto the forming tool. Fiber direction—whether aligned at 0°, 45°, or other custom angles—and the sequential placement of every ply directly determine the rim’s strength, stiffness, and overall weight distribution. A well-executed layup ensures material is concentrated precisely where loads are highest, such as spoke beds and bead seats, while eliminating unnecessary bulk in low-stress zones.

This meticulous process demands both technical knowledge and a craftsman’s touch. Technicians constantly check ply overlaps, remove trapped air, and verify ply counts against the layup roadmap. The result is a pre-cured structural foundation—strong, light, and balanced—ready to be loaded into the mold and subjected to heat and pressure. What happens at this stage sets the stage for everything that follows: the rim’s final durability, ride feel, and fatigue life.