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// 3-piece-wheels

Engineering a Modular 3-Piece Performance Wheel System

A high-performance automotive client needed a modular 3-piece wheel system that balanced weight reduction with structural integrity and simplified assembly for custom fitment applications. This case study details how we engineered a solution from initial concept to production-ready design.
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  • Weight Reduction 18% vs. reference design
  • Part Count Optimized assembly
  • Customization Multiple barrel/center combinations
  • Industry High-Performance Automotive

// The problem & the solution

The Core Challenge & Solution

The Problem

Why Existing Wheels Fell Short

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Too Heavy: Hurt vehicle performance and efficiency

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Complex to Assemble: Many small parts increased cost and time

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Hard to Customize: Limited options for different vehicle fitments

The Solution

Smart Engineering, Simple Assembly

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1. Weight-Optimized Design

  • Used FEA analysis to strategically remove material
  • Result: 18% weight reduction while maintaining strength

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    2. Simplified Assembly

  • Replaced 24+ small fasteners with one locking ring
  • Result: 30% faster assembly time

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    3. Modular System

  • Standardized interface allows endless barrel/center combinations
  • Result: Custom fitments from simple components

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    // Technical Highlights

    Precision Engineering

    Aspect Solution Benefit
    Weight
    FEA-optimized spokes
    18% lighter
    Assembly
    Single locking ring
    30% faster build
    Materials
    Forged aluminum alloys
    Strength + lightness
    Customization
    Modular interface
    Parts met design and tolerance requirements

    // Results & Impact

    Performance Delivered

    For the Driver:

    • Better handling from reduced unsprung weight
    • More customization options

    For the Manufacturer:

    • Faster, simpler production
    • Lower inventory costs
    • Stronger, safer product
    free product strategy call

    Client Feedback:

    "Core Mech were an excellent addition to my project. They leveraged considerable knowledge to make valuable recommendations and guide the design process effectively. They were flexible with multiple revisions, regularly available to discuss problems we were working through, and stuck to schedule. Most importantly, I got a high quality design at the end of the project. I highly recommend CMD if you are looking for a quality mechanical engineer/CAD expert for your next project."

    // Engineering Process

    A Proven Engineering
    Workflow

    Our engineering process is designed to deliver mechanical solutions that are accurate, manufacturable, and fully aligned with your project goals.

    01

    Discovery

    We define your goals, requirements, and technical constraints.

    02

    Concept

    Quick design options are explored to find the best approach.

    03

    CAD

    The chosen idea becomes a precise, production-ready 3D model.

    04

    Validation

    Simulations check performance, strength, and reliability.

    05

    Prototype

    We support prototype creation and refine based on testing.

    06

    Final Delivery

    Final design, drawings, and documentation prepared for manufacture.

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