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Manufacturing & Testing

Carbon Prepreg

1. Carbon Prepreg

We use Toray T800 carbon for the majority of the aero rim structure and Tokyowheel trademarked Duraheat-R™ carbon on the braking surface for increased stopping performance and durability.

Carbon Sheer

2. Carbon Sheer

Every Tokyowheel rim is made from multiple densities and tensile strengths of carbon (different materials for different structures). Over 20 separate pieces are precision cut for each rim.

Preliminary Layup

3. Preliminary Layup

The carbon prepreg is assembled around a pneumatic core that provides an outward force on the rim during carbon curing.

Braking Surface and Finish Layer of Carbon in Mold

4. Braking Surface and Finish Layer of Carbon in Mold

Before we put the carbon layup into mold, the Duraheat-R™ braking surface, and the surface layer of the carbon rim (which is effectively cosmetic), are glued into the mold.

Layup in Mold

5. Layup in Mold

The full layup is placed into a proprietary 10-piece mold, the pneumatic core is pressurized, and the carbon is cured at high temperature for 45 minutes.

Initial Roundness, Braking Surface Width, and Weight Quality Control

6. Initial Roundness, Braking Surface Width, and Weight Quality Control

We verify (with micrometers and a digital scale) that each rim’s roundness, lateral offset, and weight are within tolerances. We also test the braking surface width to ensure that the braking will be smooth and consistent.

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CNC Spoke Hole Drilling

7. CNC Spoke Hole Drilling

We use a computer controlled drilling machine to customize spoke hole position and angle to improve power transfer to the wheel.

Digital Braking Surface Testing

8. Digital Braking Surface Testing

We run the wheel up to 30kph and then apply a braking force and measure 7 performance variables - deceleration, stopping distance, average and maximum rim temperature etc. By measuring these things we are able to continuously improve the braking performance of our wheels and their durability under heavy braking conditions.

Digital Rim Stiffness Testing

9. Digital Rim Stiffness Testing

We test the stiffness of a section of rim laced to a spoke by applying a 3000 newton force to the spoke and measuring rim deflection in thousandths of a millimeter. This lets us optimize the stiffness of the rims, which results in more power transferred from the rider through the wheel into the road.

Wheelbuilding Workstation

10. Wheelbuilding Workstation

We lace the spokes to the rim and true the wheel at low tension.

Pre-Stress Break-In

11. Stress Relief & Break-In

Next we stress relieve the wheel by applying a sideways force on the hub with a machine. This essentially replaces the 'break in' period that you would experience with a new wheel and allows our wheels to stay truer throughout the life of the wheel. After a final truing they are ready for finishing.

Finished Tokyowheel

12. Finished Tokyowheel

We finish your wheels with your choice of 12 different colors, and pack them securely for shipping to your door.


BUILD PROCESS

Tokyowheel Support

We Support You

Our build process starts with support. Choosing your new wheels can be a difficult decision. We understand that and are here to help. Send us an email or give us a call and ask us a few questions about your future wheels. We will help you choose the best wheelset for you. Once you've placed an order, we keep in touch with you while your order is processing and support you after you've received your new wheels.

Handbuilt Carbon Wheels

Hand Built

Building wheels is one of the few things that machines can't do as well as humans. Although a handmade wheel and a machine made wheel might look the same initially, the hand made wheel will ride faster and more comfortably and stay truer over time. Tokyowheel master wheel-builders assemble, true, balance, and test every wheelset to exact precision standards, to ensure that your wheels perform perfectly, for as long as you own them.

Tokyowheel Carbon Wheels

Strict Quality Testing

Your wheels are built to very strict tolerance limits to guarantee you the most durable, highest performing wheels.

Build MeasurementTolerance
Roundness<0.5mm
Lateral Offset<0.2mm
Max Rim Tension300kgf
Max Spoke Tension (Front)100kgf
Max Spoke Tension (Rear)140kgf
Tokyowheel Warranty & Crash Replacement

1 Year Warranty & 2 Year Crash Replacement

SituationWarranty
Manufacturing Defects Found Within 1 yearWe will replace the faulty component and pay shipping both ways.
After 1 YearMaintenance, upgrade, and repair service at minimal cost.
You Crash and Destroy your Wheels (Within 2 Years)We will sell you a new set of wheels at 50% off.
What's Not CoveredNormal Wear and Tear