Custom Hubs

Due to the high cost of the rim customization we do, the outcome price of the rim in production is very high.

In order to keep the wheelset price low as possible, we had to produce high quality hubs that can match the quality of other high brand hubs. The cartridge of the hubs have been CNC machined in order to support our custom designed Convex/Concave Ratchet. 

Using quality materials for the hub cartridges like 6061 T6, 6082 T6 and/or 7075 T6, and precise CNC machining, we managed to produce high quality hubs at the acceptable price, and thus keeping the wheel set price more affordable then the other carbon fiber wheels sets on the market.

Due to the high cost of the rim customization we do, the outcome price of the rim in production is very high.

In order to keep the wheelset price low as possible, we had to produce high quality hubs that can match the quality of other high brand hubs. The cartridge of the hubs have been CNC machined in order to support our custom designed Convex/Concave Ratchet. 

Using quality materials for the hub cartridges like 6061 T6, 6082 T6 and/or 7075 T6, and precise CNC machining, we managed to produce high quality hubs at the acceptable price, and thus keeping the wheel set price more affordable then the other carbon fiber wheels sets on the market.

Rim Production Process

The most interesting but equally complex part of the wheel production is certainly a carbon fiber rim production, especially when most of the process is done by hand:

  • carbon fiber prepreg selection and cutting to a specific size and shape
  • layering carbon fiber stripes into the mandrel tool by hand
  • cleaning and preparing the mold
  • positioning rim layer-up configuration into the mold
  • depending on the rim type and the resin used, curing time can last from 1h up to a several hours
  • drilling holes and painting are two final steps of this process
  • as part of the QC, flatness and roundness indexes are checked, making sure they are below 0.02mm

The most interesting but equally complex part of the wheel production is certainly a carbon fiber rim production, especially when most of the process is done by hand:

  • carbon fiber prepreg selection and cutting to a specific size and shape
  • layering carbon fiber stripes into the mandrel tool by hand
  • cleaning and preparing the mold
  • positioning rim layer-up configuration into the mold
  • depending on the rim type and the resin used, curing time can last from 1h up to a several hours
  • drilling holes and painting are two final steps of this process
  • as part of the QC, flatness and roundness indexes are checked, making sure they are below 0.02mm

Stealth Black Series

Combining high-grade carbon fiber T800, right curing time, temperature and pressure inside the mold, gave us one of the lightest rims you can find on the market, with moderated stiffness providing control and comfort during long XC marathon races.

Internal nipple design demands smaller holes in rim structure, which means less carbon fiber strings been disrupted, boosting the stiffness and durability of the rim. This Bellani rim is one of the lightest you can find on the market, respecting the height and width of the rim profile, and inner nipple design at the same time. Being light and stiff, it is still proportionally elastic in order to moderate all impacts while driving over rocky and steep descents.

One of the lightest rims you can find on the market, with a great impact resistance.

Black NET Series

Having a performance in mind as a first priority, this type of Bellani rim is made out of the High-Grade UD carbon fiber T800 and T1000, cut in different directions and layered up together. Inner hole of the rim has been additionally layered with the carbon fiber sheet (3K Net, 1x1, 210g/m2), acting as reinforcement tube inside the rim itself.

Additional reinforcement defines new level of stiffness, but also adding to a rim weight as well. So, in order to stay in SL weight class, we had to use high ratio of T1000 UD for the rest of the rim structure. Internal nipple design demands smaller holes in rim structure, which means less carbon fiber strings been disrupted, boosting the stiffness and durability of the rim.

Every watt you put to the pedal, will be transferred right to the ground.

Internal nipples means stiffer rim, great design and aero profile

Every spoke hole of the rim is the weakest point of the rim structure. Regular carbon fiber rims on the market have a spoke hole that is 4.5~4.7 mm wide. In order to mitigate this structural impact, we have decided to use concept of the small spoke holes 2.3mm wide.

This makes a rim stronger, due to the less carbon strings are being disrupted, but also gives a more fluent design and aero profile while keeping nipples 'hidden' inside of the rim.

Of course, all those benefits comes with a weight penalty of having additionally 15g per rim. Due to the fact of having smaller hole in the place where the rim is the thickest, the rim weight raised up for about 15g per rim, or even more.

But nevertheless, even with this weight penalty, every Bellani rim you go with, will be one of the lightest you can find on the market. All this tells about the High Carbon Grade fiber we are using in order to mitigate all those challenges.

Every spoke hole of the rim is the weakest point of the rim structure. Regular carbon fiber rims on the market have a spoke hole that is 4.5~4.7 mm wide. In order to mitigate this structural impact, we have decided to use concept of the small spoke holes 2.3mm wide.

This makes a rim stronger, due to the less carbon strings are being disrupted, but also gives a more fluent design and aero profile while keeping nipples 'hidden' inside of the rim.

Of course, all those benefits comes with a weight penalty of having additionally 15g per rim. Due to the fact of having smaller hole in the place where the rim is the thickest, the rim weight raised up for about 15g per rim, or even more.

But nevertheless, even with this weight penalty, every Bellani rim you go with, will be one of the lightest you can find on the market. All this tells about the High Carbon Grade fiber we are using in order to mitigate all those challenges.

Smart Tubeless design

Every Bellani rim is a tubeless ready by design, by applying hookless rim design. Following this design given on the right, there are two important details 'rim bead lock' and 'rim bead seat'.

Those two things will ensure that the tire sits firm and tight to the rim on low pressures, but also once the tire is punctured and the air gets out of the tire completely.

We experienced this couple of times already, during the race, but kept driving for a mile or two, on flat tires through woods and rocks just to finish the race, keeping the rim safe and protected due to this feature.

Every Bellani rim is a tubeless ready by design, by applying hookless rim design. Following this design given on the right, there are two important details 'rim bead lock' and 'rim bead seat'.

Those two things will ensure that the tire sits firm and tight to the rim on low pressures, but also once the tire is punctured and the air gets out of the tire completely.

We experienced this couple of times already, during the race, but kept driving for a mile or two, on flat tires through woods and rocks just to finish the race, keeping the rim safe and protected due to this feature.