From alloy ingot to high-performance wheel. How is it done, and by whom?
The creation of an alloy rim is a fascinating process that involves several steps. It all starts with the alloy ingot, a massive block of an aluminium alloy. This ingot is heated in a melting furnace to over 800 degrees Celsius until the aluminium melts. This melting process is crucial and forms the basis to ensure the lightweight and highly durable material and its unique properties. The exact alloy ratio that defines DEZENT rims is one of the best-kept secrets.
Once the aluminium is melted, it is pressed into moulds, or more precisely ingot moulds, to create the basic structure of the rim. During the casting process, the mould is kept at a specific temperature to ensure a homogeneous structure.
This is carried out by the production assistants at the smelting station and the foundry. They ensure the melting process, the transport of the liquid aluminium to the casting machines, and the constant filling of the same.
Manual work is essential
After casting, the first detailed processing of the so-called preform is done to remove excess material. Here, advanced machinery and technologies, as well as good old manual work, are used to ensure absolute precision. The surface is smoothed and checked for irregularities. Subsequently, three more steps are necessary. This is carried out by the production assistants of the X-ray, mechanical processing, and burnishing departments. Constant quality control is one of the greatest denominators of the respective departments.
Eleven steps to the paint
After an internal trip to the paint facility, the aluminium rims are cleaned blank in an eleven-stage pretreatment plant, passivated, and then coated in a separate powder circuit with 100% recovery. Passivation in surface technology refers to a process that involves the targeted creation of a protective layer on a metallic material, thus preventing corrosion of the base material.
Following the cleaning process, the rims are cleaned of dust and particles by a high-performance vacuum cleaner and prepared for the actual painting process. In the so-called painting oven, a first layer of paint, the primer layer, is melted onto the aluminium rim in powder form. This colouring process is applied to materials that are unable to absorb colours and paints. By slowly heating the rim, the actual colour carrier combines with the primer layer to form an extra-strong protection. With a transparent seal, the third paint layer, the first barrier against environmental influences is created. This process is carried out by the powder coating production assistants and wet paint coating production assistants.
All TÜV or what?
Computer-calculated and mechanical simulations are only one side of the coin – through TÜV as an independent testing organisation, DEZENT also conducts extensive driving tests. Only rims that meet strict standards are approved and prepared for shipping.
With eagle eyes and a lot of routine, each individual DEZENT WHEEL is inspected and prepared for the final step of production – packaging – and released. This is carried out by the production assistants at the final inspection and packaging stations. Only when everything is neatly packed, the aluminium wheels are taken in boxes to further transport to a fully automated high-bay warehouse, but that's another story for another time.
The creation of an aluminium rim is thus a highly technological and precise process that requires a careful approach. From the melting of the aluminium ingot to the final quality control, each rim goes through many different stages to meet the highest standards and fulfil the requirements of safety, performance, and aesthetics.
To get an idea how this technological marvel looks on your vehicle, you can quickly and easily explore our 3D DEZENT rim wardrobe.
