The tension-spoke wheel is a beautifully efficient structure...
It can be a very lightweight component, yet it can also support tremendous loads. Although the basic design has not changed much over the past century, we decided to use our knowledge of the latest composite materials and rethink the design, using these materials in a whole new way.

But materials are only part of the story, simply buzzwords at this point – getting the true performance out of these incredible materials required a whole new approach to wheel construction.

Taking advantage of today's materials...
For the spokes, we use a hybrid construction with Kevlar fibers alongside carbon fibers, all within a thermoplastic resin matrix. The carbon fibers provide superior stiffness, while the Kevlar adds tremendous toughness.
This unique material is incredibly strong and fantastically light. Topolino's composite spoke material is stronger than a 14g stainless steel spoke and is only one-fifth the weight.

And light weight is only the beginning…
The thermoplastic resin and Kevlar/carbon fibers work together to significantly dampen road vibration, for a difference you can feel. While maintaining its excellent lateral stiffness and firm responsiveness, these composite spokes absorb some of the road buzz, for greater comfort and control.
We also use a special thermoplastic carbon fiber composite material for the hub shell. It has strength matching that of aerospace aluminum, but is 45% lighter.

We go all the way...
Rather than interrupting the Kevlar and carbon fibers, each spoke spans diametrically across the whole wheel. This reduces spoke stress at the hub and allows the continuous unbroken fibers in the spoke to span clear across the wheel.
With conventional steel spokes, the spokes are not well matched to the hub flange. As any wheelbuilder knows, steel spokes must be manually bent near the flange and forced into alignment to direct the spoke toward the rim.
This creates a flex point in the spoke and it is this flex and squirm of that is one of the main causes of spoke breakage due to fatigue.
In contrast, the Topolino hub and its spokes are perfectly mated into an integral unit to fully support each spoke within the hub flange. Even within the hub, each spoke is perfectly aligned with its span to the rim. Thus, the spokes are held in pure tension, with none of the fatigue-inducing movement or flex that is characteristic of conventional steel spokes.

Sensible spoke count...
Since our spokes are so light, there is virtually no weight penalty for adding a few more. This allows us to use what we call a "sensible spoke count". We lace our wheelchair wheels with 20 spokes. As compared to a 12 spoke wheel, Topolino's 20 spokes result in far better stress distribution around the rim. We are able to use a much lighter rim for lower rotating inertia while, at the same time, building a stronger wheel.

Modular construction...
In the real world, stuff happens. Crashes can sometimes occur, potholes sometimes can't be avoided, and some of us have even been known to back into the garage without taking the bike off the roof. Even though we packed a whole bunch of technology and innovation into these wheels, they were designed to be repairable and to exist in the real world. Topolino's unique spokes and hub are built as modular "wheel halves" that are laced to the rim in a conventional fashion. This means that, if a wheel does become damaged (in a crash, for instance), the individual parts are all replaceable using conventional tools and the wheel may be easily rebuilt to live again.

 

Testing: Topolino wheels prove their mettle...
At Topolino, innovation is but one part of the story. As a technology based company, the key to insuring that our wheels live up to our standards requires testing, testing... and more testing. In fact, we have created one of the most advanced wheel testing labs in the industry. A Topolino wheel must survive a rigorous gauntlet of testing before it is ever introduced to the public. But it doesn't stop in the lab; we also use a wide range of test riders from pro racers to high mileage enthusiasts and from climbers to Clydesdales. All this to insure that the wheels are the absolute best for the most important rider of all: you.

 

Craftsmanship: The final key to a better wheel...
Wheel-building robots do exist... but we don't use 'em. All of our amazing technology and innovation would be short-lived unless the wheels were built to the most exacting standards. Our skilled wheel-builders have many years of experience in their craft. Each Topolino wheel is fully built by hand and every spoke is tuned an gauged for perfectly balanced tension. We have even developed proprietary processes to insure that all of the spokes are specially pre-stressed and settled. In fact, we have the most exacting standards of final spec in the industry. The net result? A wheel that is perfectly true and round and built to stay that way.

 

 

Still interested to learn more? More technical info: Click Here