Corsaforged

FEA TESTING.

Central to our commitment to producing reliable and durable wheels is the application of Finite Element Analysis (FEA). Through comprehensive computer simulations, we meticulously evaluate the mechanical behavior of our wheel designs under various stress conditions, ensuring maximum safety and performance even in the harshest environments.

Employing advanced technology and stringent real-world testing parameters, we rigorously test our wheels in accordance with JWL, SAE, and TUV standards. This rigorous validation process guarantees that our wheels are exceptionally robust, capable of enduring the most demanding conditions.

RAW FORGING.

We start with high-quality 6061 aluminum, pressing it with 10,000 tonnes of pressure before applying T6 heat treatment. This process produces the robust 6061-T6 aluminum that forms the foundation of our wheel designs.

With a vast array of forging shapes and specifications at our disposal, we carefully choose the optimal ones for crafting your custom wheels. Depending on their size, each raw forging can weigh between 80 and 100 pounds.

Our commitment to using premium materials and meticulously selecting each forging ensures that every wheel we produce is a true masterpiece.

Lathe Turning

Next, the shaping process begins. Our operators start by placing the forging into a lathe machine, which swiftly and precisely carves out the initial wheel face and barrel profiles.

The forging is then repositioned to allow the lathe to create the profile on the reverse side. Depending on the size and complexity of the forging, this step typically takes between 15 and 30 minutes to complete.

DESIGN MILLING.

The initial rugged raw forging undergoes a sophisticated transformation, emerging as a sleek and reflective blank forging. This refinement process involves precision cutting, which effectively removes surplus aluminum, resulting in a significant weight reduction of approximately 20 to 30 pounds.

What begins as a solid, unrefined block of metal is skillfully crafted into a meticulously prepared canvas, poised for its ultimate transformation into a work of art. The lathe process, while seemingly straightforward, requires a high level of expertise and a discerning eye for detail. Each blank forging must be flawlessly crafted to meet our exacting standards, ensuring the final product exemplifies both strength and aesthetic perfection.

POST MILLING.

Upon completion of the milling process, each section of raw milled aluminum undergoes several meticulous finishing stages, including hand filing, deburring, buffing, and ceramic bead high-luster polishing. These steps are essential for preparing the wheels for their final coating and achieving the highest quality finish.

Hand filing ensures that any imperfections from the milling are expertly smoothed out, while deburring removes any rough edges or burrs that could affect the wheel’s performance and appearance. Buffing further refines the surface, enhancing its smoothness and preparing it for the polishing stage.

FINISHES

We exclusively utilize the highest quality, American-made powder coats for our wheels, offering over 40 curated finishes.

These finishes can be further customized with glossy or satin clear coats, brushed textures, and polished bases to achieve the most premium results for our clients. Additionally, we have the capability to create two-tone finishes and accommodate special color requests, ensuring a bespoke and refined appearance for each wheel.

FINAL QC.

In the final stage of our production process, we conduct rigorous quality control checks to ensure every wheel meets our high standards of precision and excellence. Each wheel undergoes thorough inspections, including runout tests and finish evaluations, before receiving a sticker. This sticker, bearing the signature of our QC inspector and noting the test results, signifies our commitment to meticulous craftsmanship and quality assurance. It serves as a mark of distinction, confirming that our wheels are crafted to exceed industry standards.