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DISCOVER HOW WE DESIGN AND BUILT WHEELS

ENGINEERING
DEVELOPEMENT

The design of LLAGOS FORGED Wheels is developed to be as lightweight as possible but with maximum resistance and FEA-tested to the load rating required for safe operation of the specific vehicle for which the wheel is being built.

 

The entire engineering and manufacturing process is carried out with the official parameters for the ISO 9001: 2015 quality management system and KBA (Federal Motor Transport Authority), certified by TÜV Thuringen and TÜV Rheinland that allow to comply all the necessary parameters and quality standards to be able to do all the European homologations.

 

All our forged wheels are designed, engineered, and FEA-tested to the exact specifications and requirements for optimal performance and fitment on your vehicle with European ETRTO standards and to be able to pass any approval such as JWL/VIA, ETRTO, ECE R124 and TÜV.

 

They are designed, engineered and manufactured in Europe with the highest quality and safety standards to achieve a TOP product with maximum lightness, resistance and quality and with a perfect finish.

 

The LLAGOS FORGED Wheels development of CAD design engineering is done with the SIEMENS program.

 

The structural calculations are carried out with one of the best and most prestigious brands (NASTRAM), which are the most reliable.

MATERIAL QUALITY

We only use the best materials of the highest quality for the manufacture of our forged wheels.

 

For the manufacture of LLAGOS FORGED wheels we use the best lightest forged aluminium of the highest quality and resistance.

 

The forged aluminum used for the manufacture is of aerospace-grade 6061 with T6 quality tempering treatment, to give more hardness to the surface of the material.

The material is forged at more than 500 degrees of temperature with hydraulic presses at a pressure of 12.000 tons.

MACHINING PROCESS

The machining process of a set of LLAGOS FORGED wheels can take several days from the moment the solid aluminium block begins to be machined until the surface finish is perfect.

 

In the machining process over 70% of the original material is removed.

Even the smallest detail of the wheels is worked in different steps as if it were a sculpture, a work of art.

 

They are machined on high-precision numerical control machines with a 5-axis articulated head machine developed for F1, providing the highest quality and technology, with a machining tolerance of 0.3 milimeters.

 

Our precision limit is 0.25 millimeters in concentricity and 0.25 millimeters in hole position.

 

For all the hole position to be below 0.25 millimeters, the overall concentricity of the holes must be a maximum of 0.14 millimeters.

FIRST TURNING: FRONT FACE
MACHINING PROCESS

The raw forging is lathe-turned outside. The material is roughened and rounded.

SECOND TURNING: INNER FACE
MACHINING PROCESS

Then flipped 180-degrees and turned inside, creating the rough profile of the final wheel. Then flipped 180-degrees and turned inside, creating the rough profile of the final wheel.

FACE MILLING: STEP 1
MACHINING PROCESS

In this step, the forged aluminum block begins to become a LLAGOS Design forged wheel and gradually acquires its design. The wheel is milled from the front. Windows are made and the shape of the wheel is milled.

FACE MILLING: STEP 2
MACHINING PROCESS

This process takes more than 6 hours.
Throughout the process, the tools are changed to gradually sculpt the wheels until the final shape is achieved.

FACE MILLING: STEP 3
MACHINING PROCESS

At the end of the face milling, the logos are engraved on the front.

MILLING FOR SCREWS AND VALVE
MACHINING PROCESS

Valve and screw holes are milled with PCD for each vehicle.

WEIGHT LOSS FROM BEHIND
MACHINING PROCESS

Once the face machining is done, the wheels are flipped 180 degrees for additional milling. The lightening pockets are milled into the back of the wheels reducing the maximum possible additional weight in this área.

ENGRAVING OF INSCRIPTIONS
MACHINING PROCESS

In this step, all the inscriptions are made on the inner edge of the wheel such as brand and
model, reference, serial number, technical specifications, vehicle application, size, offset,
identifying each wheel as an original product, numbered and genuine LLAGOS Design that meets all the technical and safety specifications required for the vehicle model for which they have been designed.

FINAL TURNING FOR AN EXTRA TOUCH OF QUALITY
MACHINING PROCESS

Small excess material is removed to center the wheel after all the turning, milling and drilling processes to remove the deformations that are created throughout the manufacturing process. The wheel is turned to eliminate all the deformations produced in all the previous machining steps. In this way, the oval and rolling that the wheel may have is eliminated with a precision of 0.25 milimeters. Thanks to all this, apart from eliminating oval and balancing, one of the most obvious things when compared with most forged wheels on the market, even those of the most prestigious brands and supercar manufacturers, is that our forged wheels practically do not need counterweights for balancing. All this is thanks to the fact that the whole process is carried out with absolute precision, with an obsession for perfection and using the most advanced technology developed for F1.

QUALITY CONTROL
MACHINING PROCESS

Once the entire process is complete, each wheel is rigorously inspected to verify that it meets all of the above quality and precision parameters. Our quality control is carried out, as in the entire manufacturing process, with the highest technology.
While most manufacturers perform quality control manually and using calipers and micrometers, we do it with a three-dimensional measuring machine with an error tolerance of 0.004 milimeters. They are designed, engineered and manufactured with the highest quality and safety standards to achieve a TOP product with maximum lightness, resistance and quality and with a perfect finish.

BLASTING PROCESS

When the machining process is finished and before the painting process begins, the wheels are subjected to the shot blasting process, without which it would not be possible to achieve a perfect final finish.

 

This process is divided into 5 steps that combine manual goldsmith work with the highest technology.

TRIMMING AND CHAMFERING
BLASTING PROCESS

This process begins with deburring. For deburring an aluminum blade is used to remove the cutting edges on the inside of the edges so that they are well rounded. In addition to rounding the edges, stresses are thus reduced and the beginnings of breakage cracks are avoided.

SANDING
BLASTING PROCESS

Sanding is used to level the different tools that are used and generate a smooth surface, so that the surface does not have bumps when painting.

BLASTING
BLASTING PROCESS

In this process, the wheels are blasted with high pressure steel spheres to prepare the surfaces and eliminate all machining finish imperfections and leave the surface completely smooth and perfect to start the painting process. Only in this way can a smooth and perfect finish be ensured. The shot blasting process also provides extra surface hardness. This process is not used regularly and most manufacturers skip it to reduce costs, but at LLAGOS Design we do not skimp on costs to be able to offer a product with the highest quality standards.

DEGREASE
BLASTING PROCESS

Once all these meticulously performed steps have been completed and the surface of the rim is perfect and fully prepared to start the painting process, a cleaning is carried out using ultrasound.

ANTIOXIDANT PRE-TREATMENT OF THE MATERIAL
BLASTING PROCESS

After the deburring and degreasing process and once the wheels are completely clean, they undergo a controlled antioxidant chemical treatment to prevent corrosion and promote paint adhesion. The European regulation ECE R124 requires a minimum durability of 394 hours in the spray salt test, while the pieces treated with our controlled antioxidant chemical treatment and lacquered with an approved paint, exceed 1000 hours of acetic fog test according to ASTM B 2087 EU regulation and the 2000 hours of salt spray testing according to ASTM B 117 EU regulation, far exceeding the parameters of the ECE R124 standard, today the most restrictive and demanding homologation standard in Europe.

PAINTING PROCESS:

As in the entire manufacturing process, the painting process is carried out in such a way that we can guarantee the highest quality of finish.

 

Our degreasing, surface antioxidant pre-treatment and painting process is homologated with the parameters of the ECE R124 standard, today the most restrictive and demanding homologation standard in Europe.

 

The painting process is carried out in 3 phases after ultrasonic cleaning:

PRIMER
PAINTING PROCESS

Molten powder primer at 230 degrees.

PAINTING
PAINTING PROCESS

High-quality liquid paint in the chosen color reference.

VARNISHING
PAINTING PROCESS

Varnishing with liquid varnish with drying at high temperature (160 degrees).