How Are Car Wheels Made? A Glimpse Into Car Wheel Manufacturers

Are you in the market for new wheels? If so, you could spend hours researching what to look for on your own. Or, you can stick with us and we'll give you some pointers.

Let's begin with the basics. When buying new wheels for your vehicle, there are many factors to consider.

In addition to size and style, there is a distinction between cast, forged and flow form wheels. For those of you who are newer to wheel lingo, this post will help you understand the manufacturing process into how rims are made.

It doesn't have to be a wheel of fortune

Depending on your driving style, you could spend a fortune on a new set of wheels. But it doesn't have to be that way.

There are quality wheels to be had that won't break the bank. A wheel's manufacturing style plays a significant role in determining its price point.

First, you should know the difference between wheels and rims. Although "wheel" and "rim" are frequently used interchangeably, they are not the same thing.

One of the several components that make up a wheel is the rim. The tire is mounted on the outside edge of the wheel, and the rim serves as a sort-of reinforcement to secure the tire to the wheel.

You can get more details from our post, Rims vs. Wheels: What is the Difference?

Now, let's review the three most common wheel types, how they are made and why it matters.

Alloy Casting Process

To make alloy cast wheels, aluminum is heated until it becomes molten. Then, with the help of a vacuum-type tool, the aluminum is cast into its final shape after being poured into a mold.

The cast is perfectly drilled and trimmed once it cools. Although the casting process is quick and affordable, it has the drawback of producing a less durable material than a forged wheel, which we cover in the next section.

The most significant pro to buying cast wheels is price. It's the least expensive way to manufacture a wheel, so you'll pay less than other styles.

The most significant cons to cast wheels is they are heavier and not nearly as strong as forged wheels.

Cast wheels are safe and great choices for regular, everyday drivers. They are not suitable for racing or off-roading. Alloy cast wheels have more chances of breaking with that type of aggressive driving, as well as a driver who frequently runs into curbs or potholes.

Forged Wheels

A forged wheel is manufactured from a large piece of solid aluminum. It's heated to extreme temperatures and pressurized to take shape. This process helps make forged wheels stronger than cast wheels.

Uniform forging produces stronger structural integrity with less material than a cast wheel. This process does cost more, causing forged wheels to be more expensive.

The advantages of forged wheels are numerous. A stronger wheel is produced by removing cavities, porosity, and shrinking throughout the manufacturing process.

And forged wheels have a tighter grain structure than cast wheels, making them mechanically stronger and improving wear resistance over time. With this technique, you also get superior handling and performance.

When deciding between forged and cast wheels, your driving style, terrain, and price point are huge factors. But there's one more type of wheel to consider. Flow form, which is our third type of wheel.

Flow Form Wheels

Flow form wheel manufacturing is a relatively new process compared to cast and forged wheels. Flow-form wheels are made using low-pressure casting spun on a specialized machine.

This machine heats the outside of the cast section and uses rollers to form the rim to get the preferred width and shape. A stronger rim is constructed using heat and pressure, followed by spinning the material.

Flow form wheels are similar to forged wheels but at a more affordable price. The result is a lighter and stronger wheel than cast, but not as sturdy as forged. You can also expect a better price point than forged wheels.

What About Steel Wheels?

An alloy of iron and carbon is used to make steel wheels. Although they are heavier, they are more durable and sometimes simpler to fix and refinish.

They don't give all the cosmetic spoke options of other wheel types because of the manner they are made — cut out on a press and welded together.

Steel wheels offer greater resistance to impact cracks, even if their weight reduces acceleration, agility, and fuel efficiency.

In addition, they are more durable against damage from deicers, gravel and brake dust, which increases their appeal for winter driving. Plus, steel wheels are typically less expensive than aluminum models.

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