made in america.
ENGINEERING / FEA TESTING.
Each set of ESR Forged wheels are meticulously designed, engineered, and crafted in our Southern California Facility. Our team at Wheelimage Corp. with over 70 years of combined forged wheel experience allows us to have full control over the quality of our process. Each order goes through Finite Element Analysis (FEA) testing to ensure the most optimal combination of lightweight, durability, and strength.
Utilizing APP raw forgings throughout the full line of our forged wheel collections. APP which produces forgings for the elite high-end automotive market such as; Aston Martin, Ferrari, Koenigsegg, Lamborghini, Mercedes AMG, Pagani, and Porsche. It was a perfect match as our forging supplier. 6061 T6 Aero Space Forged Aluminum.
The key step in manufacturing a forged wheel is lathe turning. The raw forging is lathe-turned from the front and rear, creating a profile that maximizes concavity. In this step over 70% of the original material is removed, utilizing the most weight reduction.
Once the profile is completed, the forgings are then turned over to the mill process. The mill process is where the design comes to life. As mill cycles run through a series of pre-selected tool sets and milling paths that can take up to 4 hours per wheel to achieve the utmost precision.
After the milling process is completed, each section of raw milled aluminum needs to go through many stages of Hand Filing, Deburring, Buffing and Ceramic Bead High-Luster Polishing before it is ready for its ultimate finish. This is a vital stage for our craftsmen to prep each wheel before its coating. After each wheel is filed and sculpted the wheels go through a detailed check list with zero compromises.
Each design has also been standardized with Through-Hub Pockets between the lug holes that allow for more efficient heat dissipation and reduce un-sprung mass/weight on the wheel hub. Designs are offered under 5 unique build configurations that share and individualize newly developed details.
The most time-consuming-yet-rewarding part of the finishing process is the finish stage. That is why we confidently hand chose vendors from Brisbane Australia, Tokyo Japan and Hamburg Germany. ESR Forged premium finish line offers a brushed or polished base paired with transparent powder coats to reveal the beauty and details in the design. At ESR Forged we are always learning new ways in achieving the utmost beautiful finishes in our industry.
Each one of our forged milled centers are mounted to an aluminum spun-forged outer and inner rim halves, made from 6061 T6 aircraft grade forged aluminum. Each rim half is heat treated twice and forged until the aluminum reaches full tensile strength ensuring maximum durability. All Made in the USA. The assembly stage is one of the most critical stages in the manufacturing stage. First step is to check the run-out of every wheel to guarantee the wheels are balanced to eliminate vibrations and wobbling. We chose to use Digital Snap-On® Torque Wrenches vs generic torque wrenches. One of the advantages is that it can more precisely control the amount of torque that's applied to a bolt without losing any torque capacity. No wheel will pass our quality control unless it falls below 0.010″ (10 thousandths of an inch). While industry standard complies within 0.030″ (30 thousandths of an inch), we are consistently testing run outs within 0.007″ (7 thousandths of an inch) to ensure no wheel vibrates at high speeds.
Every wheel at ESR Forged is packaged using the highest quality packaging materials all Made In America. Our boxes are engineered to be at 275 pounds per square inch burst testing with double wall technology; while the industry standard boxes are 200 pounds per square inch single wall. We go above and beyond on every stage in the wheels life, including the packaging stage. Our team chose local packaging material manufactures and consulted with Packaging Science experts to help secure the integrity of your wheels. We want you to be a life-time customer. That is why we take pride in our manufacturing process and to offer a Limited Life-Time Structural Warranty and 2 Year Finish Warranty.
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PH#: +1 (714) 993-3004