A method of making at least a component for a rim base of a multi-piece wheel for a vehicle, comprising providing a workpiece of tubular configuration and hot upset forging the workpiece in press tooling to form a part thereof to a required configuration, wherein the part of the workpiece is heated to a forging temperature in situ in the press tooling, preferably by induction heating.

An axle assembly having a wheel flange with a central opening and a slot having an end dimensioned to fit within the wheel flange central opening. A molten binder, such as molten zinc, fills the space in between the wheel central opening and the shaft end. Upon cooling, the binder locks the wheel flange and shaft together.

A vehicle wheel spoke connection, including: a rim; a hub; a plurality of spokes extending between the rim and hub with a first portion connected to the rim, a second portion opposed to said first portion and connected to the hub, a span portion between the rim and the hub, and an applied tensile load along the span portion; a bracing element including the rim and/or hub. The spoke has a longitudinal axis and is composed of reinforcement fibers in a matrix. The external surface of the spoke includes a pre-formed configured surface comprising a multiplicity of laterally outwardly projecting engagement surfaces that are longitudinally spaced. The spoke is connected to the bracing element by a longitudinal engagement comprising a multiplicity of longitudinally spaced overlie engagements associated with the spoke engagement surfaces. The longitudinal engagement supports the tensile load.

A hollow axle shaft for transmitting rotational motion from a prime mover to a wheel of a vehicle comprises an elongated member. The elongated member extends along an axis between a first end and a second end. The hollow axle shaft further comprises a flange at the first end and extending radially away from the axis for receiving the wheel. The flange is integral with the elongated member. A method of manufacturing the hollow axle shaft comprises the step of providing the elongated member comprising a material and defining a bore extending along the axis between the first and second ends, and the step of forming the flange with the material at the first end.

Disclosed herein are systems and techniques for producing complex components using a reinforced thermoplastic material. The complex components can include contoured or curved outer surfaces, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as that adapted to define a rim of the bicycle. Thermal bonding can be used to join multiple reinforced thermoplastic materials to one another in order to form a cavity of the wheel component or other complex shape. In certain examples, a portion of a tooling assembly can be pressurized to maintain a shape of the cavity during thermal bonding and cooling. This can remove the need for a sacrificial bladder or other structure that would maintain the shape of the cavity, allowing for a seamless final component, optionally absent indicia of bladder exit or other seams.

The present disclosure discloses a carbon fiber bicycle rim and a manufacturing method thereof. The carbon fiber bicycle rim comprises a ring-shaped rim body, which is integrally formed from carbon fiber. The rim body comprises an outer ring wall, an inner ring wall, and two side walls that connect the outer ring wall with the inner ring wall. The outer ring wall has an outer side that forms a semi-closed tire groove and an inner side that encloses together with the inner ring wall and the side walls to form a closed cavity. Connecting portions are arranged in the cavity. The connecting portions have one end that is connected to the outer ring wall and the other end that is connected to the side walls. The connecting portions enclose together with the outer ring wall and the side walls to form hollow channels.