Manufacturing 鈥?How a Carbon Rim Comes to Life at DRACO

We use premium thermoset carbon fiber prepreg from Toray 鈥?carbon fiber pre-impregnated with resin that cures under heat. Prepreg is stored in climate-controlled freezers, wrapped in protective film to shield from dust, heat, and moisture.

Production managers retrieve the required rolls 24 hours before layup. Thawed prepreg must be used within 48 hours for optimal performance.

While the outer surface may show different weave patterns (UD, 3K, 12K), the core structure relies on unidirectional (UD) carbon fiber for strength and consistency. Each UD sheet is cut at precise angles 鈥?0掳, 30掳, 45掳, 60掳, 90掳 鈥?to exact width and length specifications per rim design.

Key components prepared in this stage:

- Hole reinforcement patches: Small laminated carbon rectangles that strengthen drilled areas

- Carbon rods: Hand-rolled with tapered ends, critical for rim curvature and bead hook formation

Before layup begins, technicians gather all materials needed for one complete rim: sidewall and rim bed laminates, carbon rods, air bladder, and reinforcement patches. Total material weight is recorded in our order management system. All materials are packed into a waterproof bag with a serial number label for full traceability throughout production.

Technicians work on alloy pre-molds matched to the specific rim model. The layup sequence follows a precise order 鈥?from outer surface inward:

1. Outer sidewalls

2. Inner circumference reinforcement patches

3. Air bladder insertion and wrapping

4. Rim bed carbon laminates

5. Carbon rods for bead hook and curvature

Self-checks are performed throughout to catch any dust, wrinkles, or misalignment. After layup, silicone strips are applied to the rim bed to set the shape, and the assembly is weighed again 鈥?any deviation from target is flagged in the system.

Before inserting the pre-mold layup, technicians thoroughly clean the mold surface and apply a mold release layer. Once sealed into the mold, the internal air bladder is inflated to approximately 160 psi, applying pressure from inside.

Curing parameters:

- Time: 45-60 minutes (varies by product type)

- Heat: Precision-controlled for optimal resin cure

After curing, the mold is transferred to cooling and brought down to 45掳C. The raw rim is then demolded and weighed for QA verification.

After air bladder removal, each rim is drilled to customer specifications 鈥?hole count, nipple type, and lacing pattern. We use aerospace-grade precision drill bits, replaced every 40 rims to maintain accuracy.

Post-drilling, technicians deburr and inspect each hole. For road rims, 100% undergo a high-pressure tire retention test: the rim must maintain flatness within 0.3mm at 150 psi.

Rims undergo surface abrasion for optimal coating adhesion. Our default PaintFree finish is achieved through precision molding and surface treatment 鈥?no heavy paint layers. For clients who prefer painted finishes, we work with trusted coating partners to deliver smooth, durable results.

Returning from finishing, QC inspects: weight, appearance, hole quality, graphics, labels, roundness, and flatness.

For complete wheelset orders, our wheel builders:

- Lace rims to the specified pattern

- Tension spokes to uniform specification

- Perform stress relief

- True the wheel for lateral and radial runout

- Check dish/centering

Every wheelset leaves the building station ready to ride.