Rotobox is the first and still the only carbon fiber motorcycle wheel producer in the world to develop and use a unique 3 component composite. As the composite itself the one-piece hollow or solid carbon cast production process is a novelty as well. During production several different types of CNC tailored carbon fabrics are hand placed into the negative forming mold of the high precision aluminum tool.
Next the liquid epoxy resin is injected into the sealed and tempered tool under very high pressure. This process of producing the one-piece hollow carbon cast is an adaptation of the special high pressure Resin Transfer Molding (RTM) technology. Ensuring the continuous quality, safety and accuracy of the production process.
The stainless 2.5 mm steel wire is integrated in each side of the rim increasing its impact resistance of the rim edge, yet keeps the rim edge ductile. A closed rim edge where the carbon fibers are spun around the integrated steel rim wire, resulting in a rim edge without machining and thus ensuring the best quality, wheel stiffness and strength, subsequently product safety. With the industry's first 3 component composite (carbon-epoxy-steel) and its unique one-piece hollow carbon cast construction, Rotobox is redefining the quality and manufacturing standards of a whole industry. This puts us on the forefront of carbon fiber motorcycle wheel innovations.
To create solid thin spokes we use special carbon fiber yarn developed for military use. Because of the extreme mechanical properties of the fibers that we use (tensile strength 6000 MPa) and high density forging process, the cross section of spokes becomes small and compact.
The new technology achieves a high density of armature in the composite, extreme metric accuracy and a greater smoothness of the wheel surface. In addition - the wheel becomes watertight. Thanks to the High Pressure Core Technology the structural rib is placed in the inner side between the spokes, with its mission to support the stress hot spot of the wheel. High pressure cores are entirely removed from carbon cast. As a result the BOOST elegant spoke design brings greater stiffness and although the spokes are thinner the BOOST is stronger than ever, with a permissible static load of 280 kg on the rear and 180 kg on the front wheel.
The hubs are CNC machined from 7075 T651 aluminum alloy, anodized into optional color and permanently assembled to the carbon rim. Designed specifically for each motorcycle model, the Rotobox wheels are a direct replacement of the OEM-wheels and are supplied with a cush drive, sprocket carrier, spacers and a choice of ceramic or steel bearings.
Our unique technology enables combining chopped carbon fibers with woven fabric seamlessly in one-piece monocoque. We named it DRY FORGING.
The test aims to confirm the air retainability of the tires and strength of the rims, spokes and hubs. For this purpose the striker weight (Bullet FW: 450kg / Bullet RW: 470kg) is dropped on the wheel from a height of 150 mm to apply the impact load.
The test aims to confirm the durability of the rims and hubs. For this purpose a drum is rotating the wheel at a constant velocity of 80 km/h while applying the radial load (Bullet FW: 360kg / Bullet RW: 630kg for 3.000.000 cycles).
The test aims to confirm the durability of the spokes and hubs. For this purpose the wheel is fixed onto the support, while the torsional moment (Bullet FW: 470Nm / Bullet RW: 970Nm for 1.000.000 cycles) is repeatedly applied through the contact surface of the hub.
The test aims to confirm the durability of rims and hubs. For this purpose the wheel is fixed to a rotary disc, that is able to provide a bending moment (Bullet FW: 340Nm /Bullet RW: 480Nm for 1.000.000 cycles) to the center of the wheel, while rotating with a constant velocity.