Frame Development
 |
Frame study and design The frame is every single WHEELER bike's true centrepiece. And we do not settle for standard off-the-shelf frames. Instead, an experienced team of engineers starts with a frame study, resorting to state-of-the-art technologies. Then the designs and other details are defined in cooperation with the product manager in charge and the marketing department. At this early stage of the development, wishes and ideas of our sponsored athletes, retailers and distributors are implemented. |
|---|---|
 |
3D models Once a rear triangle's cinematics have proven their functionality in the simulation, a three-dimensional model of the frame is being produced on the computer. This is being checked meticulously by the product manager and the sales management. Only if everything is completely right, they agree to the production of a sample frame. |
 |
CAD construction Based on a raw frame study, exact CAD construction drawings are being made. These allow the engineers to simulate the dynamic behaviour of a suspension frame's swing arm in order to adapt it perfectly to the human anatomy. Additionally the exactly necessary strength of certain parts like a rocker link or a damper mount made of certain materials is being determined to make sure that these parts hold up to the loads that occur in real life. |
 |
Sample frame When producing a sample frame, only the finest materials and WHEELER's own CNC manufacturing plant are being used. Thanks to computers even complicated parts can be produced in a short time, subsequently putting them through their paces. «Hydro-Tube- Forming» is an increasingly important procedure which allows to press aluminum tubes into a given forms by means of highly pressurized, thus shaping the tubes and allowing for a combination of decent looks, superior strength and low weight. |
Individual parts
Based on the three-dimensional model, all individual parts are being machined on our in-house CNC lathe to the exactly right shape and accurate to a millimetre. Among other things, individual parts like dropouts with integrated disc mounts or the mounts for fenders and carriers on commuter bicycles are one of WHEELER's specialities.
EN norms
As soon as a sample frame is being finished it is being put through its paces: On a test stand, the frame is being checked for its strength according to the most recent EN norms. Only if it passes this test the frame is being approved.
Endurance test
Its up to professionals to give the definite okay for series production. Under the toughest imagineable conditions, our team riders and designers test the bicycles to their very limits. On the hardest circuits our test center «Il Cicalino» in Tuscany has to offer and in various races, they mercilessly carry the prototypes to an extreme on order to find and eliminate hidden weak points. Only if they do not see any reasons for complaints anymore, the production is being started.
