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Regis Design can build a competitive infrastructure, create net value, support worldwide logistics, and bring demand and supply in synchronization globally for your company.
Gravity Casting
The most affordable option for molds, widest selection of available manufacturers.
In this manufacturing method, the wheel mold is placed face down, molten alloy is poured in from the side and allowed to cool starting at the face. Due to the casting nature of this method, the molten alloy is most dense at the wheel face and spokes. Because the rim of the wheel is cooled last, the rim has a higher chance of being more porous.
This method is recommended for multispoke or thin spoke styles. However the molds for gravity casting are separated into two pieces, this limits the available inner rim pocketing, tolerance levels, and requires additional machining afterward.
This method of manufacturing typically has a yield rate, the weight of the final product vs the weight of the casting material, of 35%.
Low-Pressure Die
High volume option for wheel manufacturing.
In this manufacturing method, the wheel mold is also placed down, molten alloy is pressurized and pumped in starting from the face and flowing outward and up the rim. Due to the casting nature of this method, the molten alloy is cooled starting at the furthest point on the opposite side of the face. This results in a denser rim, however since the face of the wheel is cooled last the spokes have a higher chance of being more porous and weaker.
The molds for low-pressure casting are separated into four pieces, this allows for inner rim pocketing for added strength and reduced weight, and higher tolerance levels. The additional pieces required for the mold pieces add extra cost to production.
This method of manufacturing typically has a yield rate, the weight of the final product vs the weight of the casting material, of 65%.
Tilt Casting
In this method the wheel mold is placed on its side, molten alloy is placed in a crucible at the inner edge of the rim opposite the face. The entire mold is rotated 90 degrees to allow the molten alloy to flow down to the face, this method allows the alloy to fill the entire mold and excess cooling channels located at the inner rim opposite the face. The molten alloy is uniformly cooled resulting in a strong wheel, the excess metal in the cooling channels are machined off.
The molds for tilt casting are also separated into four pieces, this allows for inner rim pocketing for added strength and reduced weight, and higher tolerance levels. The additional pieces required for the mold pieces add extra cost to production.
This method of manufacturing typically has a yield rate, the weight of the final product vs the weight of the casting material, of 45%.
Fusion Forge™ Technology
Our most advanced manufacturing method featuring tilt cast alloy base wheel and room temperature flow forming with three roller wheels (available for inner and outer rims)
The die-casted piece or the molded aluminum is propped above a steel mold and onto a locking mechanism that controls the motion to initiate the forging process.
Three rollers apply extreme pressure onto the side of the wheel which will shape the aluminum using the steel mold as a guide. For off-road styling, the wheel is flipped and propped above another steel mold that fits the shape of its opposing side.
The three rollers apply the same pressure onto the side again to shape the aluminum to follow the shape of the new steel mold. Due to the high pressure, this technique allows for a stronger wheel as it does not require heat in order to permit shape change.
This results in a wheel with its material toughened through pressure alone, allowing us to deliver products much lighter than regular cast wheels. Essentially a piece worthy of being titled “FusionForge™” is constructed as we utilize multiple state-of-the-art technologies.