IDI Composites selected for high-performance carbon fiber forged wheels

Vision Composite Products (Decatur, Ala., U.S.), a developer and manufacturer of off-road, racing and after-market automotive wheels, has selected IDI Composites International’s (Noblesville, Ind., U.S) Ultrium U660 for its carbon fiber forged wheels.

Seeking a better material solution than the cast and forged aluminum alloy typically used for performance wheels, Vision launched research into composite wheels and ultimately partnered with IDI Composites International and the 3i Technology Center. The approach combines IDI Composites’ discontinuous Ultrium U660 material and A&P Technology’s (Cincinnati, Ohio, U.S.) continuous Netshape preforms in a carbon fiber forged molding process. The resulting solution is reported to enable high-volume production at costs competitive with forged aluminum wheels and are 40% less weight than cast aluminum alternatives.

“Ultrium is the ideal material for Vision’s new carbon fiber forged wheels,” states Kevin Cahill, director of composite technology for IDI Composites. “Ultrium is extremely lightweight and durable, with a beautiful appearance that has the ability to withstand extreme loads experienced on high-performance vehicles. This material ensures that these wheels will not only perform well, but the moldability of thermoset composites allows for cost-optimized and innovative design options.”

The composite wheels were tested via a continuous 48-hour, 1,415-mile road test in a 5.0 Coyote Mustang at speeds up to 100 miles per hour. The test ended due to a broken rear half shaft axle; alternately, Vision’s carbon fiber forged wheels performed well with no damage, exceeding all regulatory and industry requirements.

“Our 3i Composites Technology Center is truly an asset that helps make projects like these possible,” says Tom Flood, vice president and general manager of IDI Composites International. “The 3i Technology Center’s testing capabilities and dedicated team of composite chemists and engineers allows IDI to drive innovation and push the performance boundaries of composites beyond the value limitations of conventional materials.”