Each set of Duxpur Wheels are meticulously designed, engineered, in our Southern California Facility. Our team at Duxpur Wheels with over 20 years of combined forged wheel experience allows us to have full control over the quality of our process. Each order goes through Finite Element Analysis (FEA) testing to ensure the most optimal combination of lightweight, durability, and strength.
Duxpur Forged
7 Steps Process
1 : STARTING FROM SCRATCH
ENGINEERING | FEA TESTING
Step 1:
2: RAW FORGINGS
RAW FORGINGS | 6061 T6 AEROSPACE FORGED
Step 2:
By making the wheel a forged one piece we have eliminated any possibility of porosity. The world’s leading aircraft manufacturers use one-piece forgings for superior performance in critical structural applications.
The forging process uses high pressure and temperature to change the non-directional grain structure of the cast aluminum starting material to the high integrity multi-directional grain structure of forgings. The aluminum remains solid throughout the process as the forging dies come together and change the shape of the round cast bar to the cylindrical shape of a wheel. The forged wheel blank is then placed in a custom built spin-forging machine to spin out and forge the rim section. The resulting radial grain direction places the highest material strength in the same direction as the operating loads. The result is “premium strength”.
3: LATHE TURNING
CONCAVITY
Step 3:
The key step in manufacturing a forged wheel is lathe turning. The raw forging is lathe-turned from the front and rear, creating a profile that maximizes concavity. In this step over 70% of the original material is removed, utilizing the most weight reduction.
4: MILLING
MILLING.
Step 4:
Once the profile is completed, the forgings are then turned over to the mill process. The mill process is where the design comes to life. As mill cycles run through a series of pre-selected tool sets and milling paths that can take up to 8 hours per wheel to achieve the utmost precision.
After the milling process is completed, each section of raw milled aluminum needs to go through many stages of Hand Filing, Deburring, Buffing and Ceramic Bead High-Luster Polishing before it is ready for its ultimate finish. This is a vital stage for our craftsmen to prep each wheel before its coating. After each wheel is filed and sculpted the wheels go through a detailed check list with zero compromises.
5: PREP
PREP.
DEBURRING | CERAMIC POLISH | BRUSH
Step 5:
The most attentive yet time consuming part of the finishing process is brushing and polishing. Offered as upgraded options in every Duxpur wheel collection, brushed wheels reveal the beautiful details in the forged aluminum grain while touch-less high-luster ceramic polishing creates a mirror-like finish.
6: COLOR
FINISHING.
Step 6:
The most rewarding part of the manufacturing process is the finish stage. That is why we confidently hand chose vendors from Brisbane Australia, Tokyo Japan and Hamburg Germany. AL13 Wheels premium finish line offers a brushed or polished base paired with transparent powder coats to reveal the beauty and details in the design. At AL13 Wheels we are always learning new ways in achieving the utmost beautiful finishes in our industry.
Each component of the wheel is offered with a Gloss, Satin or Texture finish of your choice.
7: ASSEMBLY / QUALITY CONTROL
ASSEMBLY.
Step 7:
The assembly stage is one of the most critical stages in the manufacturing stage. First step is to check the run-out of every wheel to guarantee the wheels are balanced to eliminate vibrations and wobbling. We chose to use Digital Snap-On® Torque Wrenches vs generic torque wrenches. One of the advantages is that it can more precisely control the amount of torque that’s applied to a bolt without losing any torque capacity.
No wheel will pass our quality control unless it falls below 0.010″ (10 thousandths of an inch). While industry standard complies within 0.030″ (30 thousandths of an inch), we are consistently testing run outs within 0.007″ (7 thousandths of an inch) to ensure no wheel vibrates at high speeds.
Every year or 5,000 cycles we will calibrate our wrenches to ensure accuracy and safety. After each bolt and nut is torqued we mark them and have our expert assemblers sign off the wheels for packaging
