Rim profile & aerodynamic CFD optimisation: Paul Lew
Finite Element structural Analysis: Performance Engineering Solutions (UK)
Materials and rim layup: Textreme Innegra/Toray carbon spread tow – Paul Farrell
Spokes & nipples: Sapim CX-Ray NDS. CX-Sprint DS. Brass Polyax nipple
Hubs: Industry 9 Torch featuring Enduro sealed bearings
Introducing the world’s first and currently only aerodynamically optimised gravel wheelset using a composite rim structure specifically optimised for improved impact resistance and lower tuned vertical stiffness for improved compliance.
Introducing the world’s first and currently only aerodynamically optimised gravel wheelset using a composite rim structure specifically optimised for improved impact resistance and lower tuned vertical stiffness for improved compliance.

BACKGROUND
All mass produced carbon composite wheel rims are constructed in one of two ways using an intermediate “sporting grade” modulus of carbon fiber thread. Almost exclusively P.A.N. (propylene+ammonia) based fibers are used and as a general rule ‘the better the PAN the better the fibre’ is true.
Japanese Toray is an industry leader but despite common claims, not all wheels use Toray fibres. Many cheaper inferior fiber grades are now commonplace. Visually they are impossible to tell apart to the consumer.


All composite components are manufactured using multiple layers of pre-cut fibres in either woven or uni-directional form. All other parameters being equal, the number of layers
and orientation of the fibres determine the final mechanical properties of the product once cured in a mould which is heated and thermally activates and sets the epoxy resin surrounding the fibres.
Cutting the required fibre shapes and ‘laying up’ to create the final structure has traditionally been done exclusively by hand and is therefore intensely labour dependent and final quality depends on skill established over many years.
Recently expensive semi-automated equipment has been developed to build up parts of the rim structure using the tape winding method. This has many advantages including highly accurate and repeatable fibre orientation, consistent fibre overlap and most importantly, the fibres are kept under tension (which is not possible using hand layup). Nex-Gen rims use the automated tape winding process.
Introducing the world’s first and currently only aerodynamically optimised gravel wheelset using a composite rim structure specifically optimised for improved impact resistance and lower tuned vertical stiffness for improved compliance.
Introducing the world’s first and currently only aerodynamically optimised gravel wheelset using a composite rim structure specifically optimised for improved impact resistance and lower tuned vertical stiffness for improved compliance.

WHAT ARE THE BENEFITS OF USING INNEGRA FIBER?
• Reduced weight
• Increased damage tolerance
• Increased impact resistance
• Reduced maintenance
• Incredible strength to weight ratio
• Hydrophobic (doesn’t absorb moisture)
• Dampens vibration
• Disperses energy
Innegra / Carbon Spread Tow
ISO 4210 impact test
Tape-wound carbon

Measuring lateral & vertical compliance
The Nex-Gen Innegra/carbon rim is approximately the same weight as a regular carbon composite version yet has 15% less compliance (compressive stiffness) for a more comfortable ride and exceeds 160J ISO impact without fracture compared to 140J for pure carbon composite version before fracture.
DT-Swiss vs Nex-Gen
