Abstract: A composite wheel assembly and method of construction thereof is provided. The composite wheel assembly includes a lightweight annular aluminum barrel having an inner surface and an outer surface configured to support a tire thereon. A lightweight metal central hub assembly is fixed to the barrel. The metal central hub assembly includes a central hub portion and plurality of support spokes extending outwardly from the central hub portion to free ends, wherein the free ends are fixed to the inner surface of the aluminum barrel. A wheel cladding contrasting in at least one of material type, color, texture and surface finish to an outwardly facing surface the central hub assembly is fixed to the outwardly facing surface of the central hub assembly.

Abstract: A composite wheel assembly and method of construction thereof is provided. The composite wheel assembly includes a lightweight annular fiber-reinforced barrel having an inner surface and an outer surface configured to support a tire thereon. A lightweight metal central hub assembly is fixed to the barrel. The metal central hub assembly includes a central hub portion and plurality of support spokes extending outwardly from the metal central hub portion. A wheel cladding contrasting in at least one of material type, color, texture and surface finish to an outwardly facing surface of the central hub assembly is fixed to the outwardly facing surface of the central hub assembly.

Abstract: A preform for fabricating a wheel rim and a method of making a preform is provided. The preform includes a main section and at least one secondary section, each section being formed from composite materials, such as triaxially braided composite material that includes fibers oriented in at least three directions. The main section forms at least part of a lateral section of the preform and the secondary section forms at least part of a radial portion of the preform, the radial portion of the preform being generally perpendicular to the lateral section of the preform. The preform is fabricated from a plurality of composite layers, at least some being custom composite layers having a plurality of axial fibers interwoven intermittently with substantially consistent first and second sets of biased fibers. In some embodiments, the preform is initially fabricated in an intermediate configuration prior to being moved to a final configuration.

Abstract: Disclosed is a method of forming a wheel assembly consisting of a wheel portion and a cover portion. The method includes handling the wheel portion from dunnage to a work cell with an outboard face of the wheel portion facing away from a supporting surface. Next, determining a planar position and a rotational position of wheel portion and retrieving the cover portion. The method proceeds with applying an adhesive to at least one of the back side of the cover portion and the outboard face of the wheel portion. Then, aligning the cover portion with the wheel portion utilizing the planar position and the rotational position. The next step is engaging the cover portion and the wheel portion with one another and maintaining the wheel portion in engagement with the cover portion for a predetermined amount of time with a predetermined amount of pressure to form the wheel assembly.