Wheel development
From the first sketch to the homologated wheel.
In addition to developing and manufacturing our own wheel designs, we specialise in realising customer projects. We support you from the first sketch to the finished product and take care of design, manufacture, surface finishing and testing.
- from 100 piecescustomer projects in series
- up to 24 inchblanks in the multi-axis machining centre
- 3 stepsfrom design to homologation
How we develop
Mainhattan-Wheels Leichtmetallräder GmbH
We design our own wheel designs
Mainhattan-Wheels Leichtmetallräder GmbH is dedicated exclusively to the development of modern wheel designs. In addition to developing and manufacturing our own wheel designs, we also specialise in realising customer projects. We support our customers from the first sketch through to the finished product.
Extensive know-how is required here, not least because of the comprehensive safety and testing requirements. We are a wheel manufacturer ourselves: the machines on which customer wheels are created are the same ones we use to manufacture and coat our own collection. In manufacturing we rely on the low-pressure casting and flow forming processes, and for forged wheels on blanks made from a specially developed aluminium alloy.
The three steps of wheel development
Technology wheels up to 24 inch for cars, SUVs and motorsport are always created in the same sequence.
- 01
Step 1: determining the application and design
It begins with the question of what the wheel is built for: vehicle, use on the road or in motorsport, brake system, bolt pattern, offset and load rating. For non-standard brakes we draw the brake contour and place it within the contour of the wheel. In motorsport, additional criteria such as the ventilation drag of the spokes come into play, which influences the number and contour of the spokes. From this the design drawing is created.
- 02
Step 2: manufacture and surface finishing
Depending on quantity and requirements, the wheel is manufactured by low-pressure casting, by flow forming or from a forged blank. Small series and individual designs are milled in the multi-axis machining centre from blanks up to and including 24 inch. Spokes can be back-milled and back-turned to remove material without affecting strength and load rating. The complete surface finishing with powder and wet paints takes place in our in-house coating facility.
- 03
Step 3: homologation
For use on public roads under the StVZO (German Road Traffic Licensing Regulations), the wheel is tested and receives an ABE (general type approval) or a component approval depending on the vehicle. Only then is a wheel finished. We tell you before delivery whether an entry in the vehicle documents or a presentation at the TÜV is necessary.
Manufacturing in-house
A UROS wheel on its way through our wheel machining centre: contour capture, CNC machining, cut and coated wheel.
Volume and testing
Quantities and costs
With your own wheel, manufacturing is not the only cost. Development, drawing, testing and tooling costs are added and are only spread sensibly from a certain production volume.
Series from 100 pieces
As a rule we develop customer wheels from a minimum quantity of 100. Below that, development, drawing, testing and tooling lead to extremely high costs per wheel.
Small series from the blank
Compared with other suppliers we can offer attractive prices even for small series, because we mill wheels individually in-house from a blank. The Monte Carlo F, for example, was created as a small series in this way.
Individual bolt pattern and offset
Since we manufacture the wheels largely ourselves, we can take bolt pattern, offset and other specifications into account individually, even for existing designs.
Safety and testing
Our wheels are developed, manufactured and tested exclusively for use on public roads in accordance with the StVZO. Every order is checked by our team for fit with the specified vehicle and for the corresponding TÜV approval. Depending on the approval document:
- ABE without condition A01: no entry in the vehicle documents, no presentation at the TÜV.
- ABE with condition A01: presentation at the TÜV; the inspector issues a fitting confirmation according to § 19 StVZO. No entry in the vehicle documents.
- Component approval (Teilegutachten): presentation at the TÜV and entry in the vehicle documents.
Complete wheels include laser-guided balancing with balance weights. For vehicles with an active tyre pressure monitoring system, TPMS sensors can be ordered as an option for certain models; we fit and program them.
If a wheel is processed or modified at the customer's request beyond pure surface finishing, the type approval lapses. Details are set out in our terms and conditions.
Our designs
Designs from our own development
Three examples from our collection show how different the signature can be.
ELiTE
The ELiTE design impresses with the precise lines of its contours, giving it a very technical look. The wide range of finishes sets special accents on almost any vehicle paintwork.
Learn more
MANAY
The MANAY impresses with its angular V-spoke lines and, thanks to its polished contour edges, looks even more premium and particularly technical. The finish in Gold Matt sets additional accents.
Learn moreUROS
The UROS design impresses with the precise lines of its contours. A highlight from Italian design studios for absolute individualisation, in many finishes.
Learn more
Frequently asked questions about wheel development
Can you also build four individual wheels for my car?
In principle that would be possible. However, such a project leads to extremely high costs per wheel. As a rule we develop customer wheels from a minimum quantity of 100. Since producing your own wheels incurs not only the manufacturing costs but also, for example, development, drawing, testing and tooling costs, this only really makes sense from a certain production volume for cost reasons. Compared with other suppliers, however, we can offer attractive prices even for small series, because we can mill wheels individually in-house from a blank.
Can you supply existing designs with an individual bolt pattern and offset?
Since we manufacture the wheels largely in-house, we can also take your specifications and wishes into account individually. This applies not only to bolt pattern and offset. In our multi-axis machining centre we are also able to mill individual designs from blanks up to and including 24 inch.
Which centring rings are fitted in the wheels?
Aluminium centring rings are fitted in the wheels, unless the wheels are drilled to a fixed pattern and no centring rings are required. Whether and which rings are used is shown in the list on the order confirmation or invoice.
Do I have a warranty on the wheels?
Unlike most wheel manufacturers, we grant a 24-month surface warranty on all products.
Your idea is our brief.
Send us your sketch or your requirements. We will get back to you with an initial assessment of feasibility, quantity and cost.