The quality lies in the intricate and labor-intensive process of crafting our tailor-made Forgelite™ wheels from high-quality materials. Join us on a journey as we delve into the creation of Forgelite Wheels.
When it comes to creating exceptional wheels, we believe that every step of the process counts.
We start with engineering CAD (Computer-Aided Design) software to bring our vision to life.Our team takes the customer's vehicle and fitment information and uses it to produce detailed 2D and 3D drawings of the wheels. Each set of wheels is crafted with the utmost precision, engineered with the singular goal of delivering the lightest and strongest product possible. But it doesn't stop there. We go the extra mile to ensure that every set of wheels we create is tailored to the specific needs of the client.
It's not just about creating a set of wheels - it's about crafting a piece of art that perfectly complements the vehicle it's made for. And we're committed to making that a reality, one wheel at a time.
At the heart of our commitment to producing reliable and durable wheels is our use of FEA, or Finite Element Analysis. By subjecting our wheel designs to rigorous computer simulations, we're able to accurately assess their mechanical behavior under stress, ensuring maximum safety even under the most extreme conditions.
Using state-of-the-art technology and real-world testing parameters, we put our wheels to the test against JWL, SAE, and TUV standards. This guarantees that our wheels are robust enough to withstand even the most demanding situations.
So, whether you're hitting the track or cruising the open road, you can rest assured that your wheels are up to the challenge. At Forgelite Wheels, we don't compromise on quality - and neither should you.
Using high-quality 6061 aluminum, we begin by pressing it with 10,000 tonnes of pressure before subjecting it to T6 heat treatment. This produces the 6061-T6 aluminum that serves as the foundation for our wheel designs.
With hundreds of different shapes and specifications of forgings available, we meticulously select the ones that will be used to create your custom wheels. Each raw forging can weigh up to 80-100 lbs, depending on its size.
By using only the best materials and carefully selecting each forging, we're able to ensure that every wheel we create is a masterpiece in its own right.
it's time to put it through the shaping process. Our operators begin by loading the forging into a lathe machine, which quickly and efficiently cuts out the initial wheel face and barrel profiles.
The operator will then flip the forging around and repeat the process to create the profile on the back side. Each forging takes between 15 to 30 minutes to complete this step, depending on its size and complexity.
The once-rugged raw forging is transformed into a sleek and reflective blank forging. Through the precision cutting process, excess aluminum is removed, resulting in a weight reduction of approximately 20 to 30 lbs.
What was once a solid block of metal is now a carefully crafted canvas, ready to be transformed into a work of art. And while the lathe process may seem simple, it requires an expert hand and a keen eye for detail to ensure that each blank is perfectly crafted.
As part of our three-stage quality control process, the first check takes place immediately after the blank forging has been created.
This critical step ensures that the blank has been produced to exact measurements in accordance with our engineering drawings.
During this initial quality check, we meticulously inspect all critical dimensions, including the center bore and offset, to guarantee that it meets our rigorous standards for quality and precision.
By catching any potential issues early on in the process, we're able to ensure that our finished wheels are not only beautiful but also safe and reliable.
Once the wheel blank has passed our rigorous initial quality check, it's time to move on to the next step in the process. This involves placing the blank into a state-of-the-art vertical CNC milling machine.
Equipped with a range of precision cutting tools, the CNC machine is capable of creating intricate spoke designs with unparalleled accuracy and precision. Depending on the complexity of the design, this process can take up to 8 hours per wheel, ensuring that every detail is perfect.
In our state-of-the-art CNC milling machine, we use precision cutting tools to carve out intricate spoke designs for our wheels. As the machine works its magic, it gradually cuts away material in the spaces between the spokes to create the final design.
Take our Forgelite Wheels Monoblock SV03, for example. This stunning design can take up to 5 hours to cut due to its complex spoke side profiling. Cheaper forged wheel brands are typically limited by their allotted milling time to produce them in mass quantities, this results in a more simplified spoke design.
By the time the machining process is complete, the wheel will have shed between 75% and 80% of its weight compared to the raw forging it began as, resulting in a lightweight yet incredibly strong finished product.
At Forgelite Wheels, we're committed to producing the lightest and strongest wheels possible. That's why we offer a back pocketing service free of charge with each set of wheels we make.
This process involves removing excess material from the back of the wheel, reducing its weight by an additional 1-3 pounds without compromising on strength or durability.
A freshly milled out Forgelite Wheels monoblock FL1. In its rawest aluminum form.
We understand that a flawless finish is essential for showcasing the beauty and craftsmanship of our wheels. That's why we take great care to prepare each wheel thoroughly before applying any finishes.
Our cleaning process is designed to remove any contaminants from CNC operations or handling, ensuring optimal adhesion for the powder coating. Once the cleaning process is complete, the wheel is ready for its custom finish. Depending on the finish chosen by the client, the wheel may undergo additional finishing steps to achieve the desired look and feel.
we take pride in offering premium finishes that are truly reflective of our dedication to quality and craftsmanship. Our Mirror Polish finish is a shining example of this commitment.
To achieve this flawless finish, our team of experienced artisans employs a meticulous process that involves both machine and hand polishing. The machine polishing provides a smooth surface, while the hand polishing adds an extra level of refinement to ensure that every inch of the wheel is perfect. The result is a mirror-like finish that reflects the beauty of the wheel and the skill of our craftsmen.
The hand brushed finish is a highly sought-after texture that adds depth and character to wheel finishes. This unique finish is often applied under transparent candy colors to create a stunning visual effect.
Creating this finish is a labor-intensive process that requires a skilled craftsman to carefully brush the surface of the wheel by hand. Depending on the complexity of the wheel design, this process can take up to 8 hours to complete for a single wheel. However, the end result is well worth the effort, as it adds a level of refinement and exclusivity to the wheel that cannot be achieved by mass-produced wheels.
The following step involves preparing the wheels for powder coating, including masking the lug holes, mounting pad surface, and knurled beads on the wheels.
We only use the highest quality powder coats Made in the USA on our wheels and provide 40+ curated powder coat finishes.
These finishes can be combined with glossy or satin clear coats, as well as brushed textures and polished bases to create the most premium finishes for our clients. Additionally, we are capable of producing two-tone or accomodate special-requested colors.
This is the final glimpse of the FL4 set before entering the curing oven. The curing time varies from 1-2 hours depending on the powder coat and finish selected.
We perform runout checks on all wheels to ensure their roundness. Our QC standard is 0.02"/0.51mm, but we often achieve 0.01"/0.30mm in final tests, surpassing the industry standard of 0.03"/0.76mm. A lower runout means no vibration when driving at high speeds, ensuring a smoother ride.
As the final stage of our wheel production process, we perform the most rigorous quality control checks to ensure that every wheel meets our high standards of precision and excellence.
Only when the wheels have passed all our strict QC procedures do they receive the ultimate stamp of approval: a sticker that notes the runout test results and bears the signature of our QC inspector. This sticker serves as a badge of honor for the wheels, confirming that they have been crafted to the highest standards of precision and quality.
After the final QC, we carefully package the wheels, ensuring that they are protected during shipping, we ship worldwide and take great care to ensure that each wheel arrives in perfect condition, ready to be mounted on its new vehicle and admired by all.
We appreciate you joining us on this behind-the-scenes journey of our wheel production process. We hope that it has provided you with valuable insights into how we create our high-quality wheels. If you have any further inquiries or would like to learn more about our products and services, please don't hesitate to contact us. We are always here to assist you and answer any questions you may have.
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