A method of manufacturing a rim includes placing at least one braided sleeve on a core dimensioned to define a shape of an internal wall of the rim. The method includes inserting the braided sleeves placed on the core, inside a mold that is dimensioned to define a shape of an external wall shape of the rim. The method further includes injecting a resin inside the mold to contact the mold and impregnate the sleeves and other layers with resin. The method also includes curing the resin to form the internal and external walls of the rim and obtain a cured rim having the core connected thereto. The method further includes removing the cured rim and core from the mold and melting the core to get it out of the rim.

A vehicle wheel having a rim, a hub, a plurality of spokes extending between said rim and said hub, rim and/or hub includes a spoke bed wall with an outboard bed surface, an inboard bed surface, and a spoke hole therethrough having a longitudinally inboard entrance. The spoke includes: a first spoke portion and a second spoke portion longitudinally inboard of the first spoke portion and laterally outboard of the first spoke portion, including a transition surface therebetween. The spoke extends through the spoke hole and at least a portion of the transition surface is longitudinally outboard of the inboard entrance and the spoke is connected to the rim and/or hub at the first spoke portion.

A composite bicycle rim, and a process for manufacturing the rim, having a plurality of perforated spoke-attachment seats having spaced apart first and second areas of cut structural fibers. The second area has both end portions of cut structural fibers having a longitudinal dimension greater than the first area's cut structural fibers and continuous structural fibers. At least some of the end portions of the second area's cut structural fibers are mutually juxtaposed or interposed with respect to the second area's continuous structural fibers.

A bicycle wheel rim made at least partially of a stratified composite material comprising structural fibers incorporated in a polymeric matrix. At least one opening, which passes through at least one first layer of composite material, is provided and at least one spoke attachment hole, which passes through at least one second layer of composite material, is also provided. The spoke attachment hole is completely contained within the opening in the first layer. A related manufacturing process is also described.

A bicycle wheel rim, comprising a wall made of composite material having a plurality of perforated spoke-attachment seats, wherein each perforated seat is delimited by at least one first area comprising an amassment of continuous structural fibers and at least one second area circumferentially spaced apart from said first area and comprising cut structural fibers. A process for manufacturing the aforementioned rim is also disclosed.

An insert for the rim of a spoked bicycle wheel that has a spoke hole. The insert has a portion configured to abut against a spoke attachment element with an enlarged head and a holding element that prevents movement of the spoke attachment along said longitudinal axis of the spoke hole.

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.

A wheel with flexible spokes, including a rim and hub, and spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The spokes are also flexible and resilient such that they can bend while retaining their integrity and strength.

Described herein are aerodynamic wheels. According to some embodiments there is provided a wheel for a vehicle comprising: a rim; an inner hub; an attachment assembly configured to couple rim to inner hub; a first air engaging flexible and aerodynamic surface overlaying the attachment assembly configured to couple rim to inner hub and operatively connected to the inner hub and the rim, forming a first axial surface of the wheel; and a second air engaging flexible and aerodynamic surface overlaying the attachment assembly configured to couple rim to inner hub and operatively connected to the inner hub and the rim, forming a second axial surface of the wheel, which is axially opposed to the said first surface of the wheel; wherein said first air engaging flexible and aerodynamic surface and second air engaging flexible and aerodynamic surface are adaptable to external forces and change shape, when subject to such external forces.

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.