From the first draft to the shipment

Five-, seven- or a multi-spokes wheel? Cross-spokes or double spokes? “The most important thing is passion,” explains AEZ chief designer Christian Haderer. “Ever since my teenage years, I have been passionate about two things – cars and design,” says the designer. As a manufacturer of safety-relevant components for cars, passion is one of the main pillars at AEZ. This “life motto” is reflected in all developmental steps, from the first draft to the finished product.

AEZ production “Made in Germany”

During the entire manufacturing process, all light alloy wheels undergo continuous tests according to the highest quality criteria for dimensional accuracy, material homogeneity, surface condition, density, and for visual defects. New designs and wheel developments are inspected by the TÜV Austria and the TÜV Nord for maximum load-bearing capacity prior to production approval.

Essential steps done by hand

Despite a high level of automation, the human factor is essential in the complex production process of AEZ rims. The manufacture of alloy wheels is carried out by low-pressure casting where liquid aluminium is pressed from the lower part into the permanent mold – the rim mold – using a tubing. This is followed by the precise removal of ridges in a post-treatment step done entirely by hand. The next step, bolt holes and the valve bore for the air valve are formed.

SR3 paint

The abbreviation stands for “Salt Resistant” while the number refers to the 3-layer process – primer coat, paint coat, finish coat. The primer is always an ultra-hard powder paint in black or light-grey, applied electrostatically and then “baked on” at 210°C for 45 minutes. As the actual “colour carrier” a modern wet coating is applied at roughly 180°C. As a transparent sealing and first line of defence against environmental influences, premium clear lacquer is the finish coat.

Organised chaos

It’s 49 meters wide, 100 meters long and 24 meters high, and inside of it there’s sheer chaos. We are talking about the ALCAR Group’s high-tech high-bay warehouse in Balve, North Rhine-Westphalia, Germany. This is where up to 700,000 passenger car wheels wait to be shipped to trade partners all across Europe. That’s our passion.

Our passion. Your wheel.