Author Topic: BladeX: 15 Years of Carbon Wheel Manufacturing, Now Building Wheels for Riders  (Read 18614 times)

Jason_BladeX

Hi there! It’s awesome to have you here. You asked for it, so here is a quick sneak peek behind the scenes!

Check out this short clip from our daily factory routine. What you’re seeing here is the compression molding stage. We put the prepped rim (with all the carbon layers precisely laid up) into the mold and crank up the heat.

Under intense heat and internal pressure, the resin melts and flows through every little gap, baking all those individual carbon layers together into one solid, super strong rim. This is exactly how raw carbon sheets turn into a high-performance wheelset!

Let me know if you want to see more of the building process, like drilling or wheel lacing. Happy to share more!

Newbie here I would like to see factory images and video to see how these wheel are made, and get another understanding.
Great resource for information here  :)
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

PLiving80

Hi there! It’s awesome to have you here. You asked for it, so here is a quick sneak peek behind the scenes!

Check out this short clip from our daily factory routine. What you’re seeing here is the compression molding stage. We put the prepped rim (with all the carbon layers precisely laid up) into the mold and crank up the heat.

Under intense heat and internal pressure, the resin melts and flows through every little gap, baking all those individual carbon layers together into one solid, super strong rim. This is exactly how raw carbon sheets turn into a high-performance wheelset!

Let me know if you want to see more of the building process, like drilling or wheel lacing. Happy to share more!


Thanks I am happy to see more of the process as this is not something I have seen before and is very interesting to see.
I read everywhere it is very labour intensive process to make a rim how long from start to finish is the process to make one rim

Jason_BladeX

Glad you found it interesting! You are right, making a carbon rim is incredibly labor intensive. Most of the work is done by hand, except for the material cutting and rim drilling which are done by machines.

From raw carbon prepreg sheets to a finished rim ready for boxing, there are a lot of steps:

Material Cutting -> Layup & Preforming -> Molding & Curing -> Demolding & Initial Inspection -> Drilling -> Sanding & Finishing  -> Final Quality Control

So just for the rim itself, you are looking at about 4 to 5 hours of solid work.

If we are talking about a complete wheelset (building it up with the hub, spokes, tensioning, and multiple rounds of stress-relieving), it takes even longer to ensure it stays dead true for thousands of miles.

Let me know if you want to see how we drill the holes or how a rim is checked for the runouts next!



Thanks I am happy to see more of the process as this is not something I have seen before and is very interesting to see.
I read everywhere it is very labour intensive process to make a rim how long from start to finish is the process to make one rim
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

PLiving80

Glad you found it interesting! You are right, making a carbon rim is incredibly labor intensive. Most of the work is done by hand, except for the material cutting and rim drilling which are done by machines.

From raw carbon prepreg sheets to a finished rim ready for boxing, there are a lot of steps:

Material Cutting -> Layup & Preforming -> Molding & Curing -> Demolding & Initial Inspection -> Drilling -> Sanding & Finishing  -> Final Quality Control

So just for the rim itself, you are looking at about 4 to 5 hours of solid work.

If we are talking about a complete wheelset (building it up with the hub, spokes, tensioning, and multiple rounds of stress-relieving), it takes even longer to ensure it stays dead true for thousands of miles.

Let me know if you want to see how we drill the holes or how a rim is checked for the runouts next!

Of course I would like to see more. Photos and video of the processes involved as these are interesting to see if you could post more this would be great thanks

Jason_BladeX

Glad you're enjoying this! Here is a quick clip of one of our quality control steps: the inflating test.

Before we even pump it up, our standard for the raw rim's lateral runout is already ≤ 0.2mm. By the way, good lateral runout is the key to getting a narrow spoke tension range during wheel building, and a narrow tension range is the key to a longer lasting wheelset.

Then we mount a tire and crank the pressure up to 130psi to simulate an extreme real world riding condition. Even under that high pressure, the rim must maintain a trueness of ≤ 0.25mm to pass QC.

If it shifts beyond that, it means the carbon structure isn't stable enough and it gets rejected.

Enjoy the video!

Of course I would like to see more. Photos and video of the processes involved as these are interesting to see if you could post more this would be great thanks
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

PLiving80

Glad you're enjoying this! Here is a quick clip of one of our quality control steps: the inflating test.

Before we even pump it up, our standard for the raw rim's lateral runout is already ≤ 0.2mm. By the way, good lateral runout is the key to getting a narrow spoke tension range during wheel building, and a narrow tension range is the key to a longer lasting wheelset.

Then we mount a tire and crank the pressure up to 130psi to simulate an extreme real world riding condition. Even under that high pressure, the rim must maintain a trueness of ≤ 0.25mm to pass QC.

If it shifts beyond that, it means the carbon structure isn't stable enough and it gets rejected.

Enjoy the video!

Many thanks I will be happy to see any more photos or video you have as the process is fascinating 130psi!
Have you any videos of your wheelset finished build like the Ultra as this is what I have been looking at, I appreciate picture on website but a video clip would be better  :)
Have you any Promo or Discount codes available as well?
And have you any new wheelsets/rims in development you can discuss at all? anything planned you can share?
I only ask as the technology is moving so quickly now but the time you buy something these day something new follows the next day!  :-\

Jason_BladeX

Sure, I uploaded a video of the Ultra 50D. It's about the rear wheel fully built and going through the Radial & Lateral Tolerance Check. Since it's not possible to upload large files directly here, you can take a look at it on https://bladexcycle.com/tech/carbon-wheel-lateral-radial-tolerance-check

But currently, these wheels are only for rider testing right now, so it might be better for you to come back a bit later when they are fully released. You can absolutely use the coupon code for a 15% discount then: chinertown

And yes, we do have a new product under development, but the process will be quite long. The core idea is to transform the crosswind into forward torque, making you ride even faster.


Many thanks I will be happy to see any more photos or video you have as the process is fascinating 130psi!
Have you any videos of your wheelset finished build like the Ultra as this is what I have been looking at, I appreciate picture on website but a video clip would be better  :)
Have you any Promo or Discount codes available as well?
And have you any new wheelsets/rims in development you can discuss at all? anything planned you can share?
I only ask as the technology is moving so quickly now but the time you buy something these day something new follows the next day!  :-\
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

Joe45

Sure, I uploaded a video of the Ultra 50D. It's about the rear wheel fully built and going through the Radial & Lateral Tolerance Check. Since it's not possible to upload large files directly here, you can take a look at it on https://bladexcycle.com/tech/carbon-wheel-lateral-radial-tolerance-check

But currently, these wheels are only for rider testing right now, so it might be better for you to come back a bit later when they are fully released. You can absolutely use the coupon code for a 15% discount then: chinertown

And yes, we do have a new product under development, but the process will be quite long. The core idea is to transform the crosswind into forward torque, making you ride even faster.



Great thanks for the videos super interesting stuff.
Well the new product certainly sounds interesting.
Can you share anything yet? When do you hole to have it ready yet?
Is it like one of these wavy profile wheels?

Jason_BladeX

Hey guys, just finished a quick photo shoot for our latest batch. Here are a few high-res shots of the rims and the branding details.
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

Jason_BladeX

Thanks! I’m glad you liked the content.

As for the new project, it’s still in the early stages. The 3D modeling and initial CFD data look promising, but to clarify, it’s not a wavy rim profile. Instead of just trying to 'cheat' the wind like traditional rim shapes, we're experimenting with an integrated windmill-inspired geometry. The goal is to use the rim surface itself to create a pressure differential that potentially turns crosswinds into a source of positive torque.

I’m currently debating how much detail I should share at this point, but I really like the idea of turning this into an 'Open R&D' project. There’s something special about designing with the community's input rather than just dropping a finished product later.

Let me refine a few things on our end, and I'll see what I can share soon.




Great thanks for the videos super interesting stuff.
Well the new product certainly sounds interesting.
Can you share anything yet? When do you hole to have it ready yet?
Is it like one of these wavy profile wheels?
Founder of BladeX Bicycle. 15 years in carbon manufacturing. Here to discuss engineering & answer your tech questions.

info@bladexcycle.com
https://bladexcycle.com
https://www.instagram.com/bladexbicycle/

PLiving80

Well this brand has definitely piqued my interest   :)

There's not a huge amount of owner feedback out there yet, which is understandable as they seem fairly new to the market,
But they appear to be doing some interesting things and offering a lot of performance for the money.

Has anyone here actually ordered a set yet, or got a set on the way?
I'd be interested to hear some real-world feedback once people start putting some miles on them.
Things like build quality, ride feel, hub performance, spoke tension, long-term reliability, and how the wheels compare to some of the more established Chinese brands.

The specs look good on paper, but that's only half the story. It would be great to see some owner photos and hear some honest opinions from people who have actually taken the plunge.
At the moment it feels like one of those brands that could either be a hidden gem or simply too new for much feedback to be out there yet. Either way, it's certainly caught my attention.
Problem is they so much out there I am dicovering now its makimg it so hard to choose!

Sander2177

Hey Everyone

I thought I’d add a proper update here now that I’ve actually got some meaningful riding on these wheels.

Disclosure first: these wheels were supplied to me free of charge by BladeX for testing. I didn’t approach BladeX asking for a wheelset — Jason Xiang, the founder of BladeX, initially contacted me around the beginning of June, so we’ve now been speaking for roughly 3 months.

When Jason first contacted me, I’ll be honest, I have never heard of the  BladeX name and there was notimg online when i had a look maybe a few YT video from mayb 10 or so years ago and some instagram stuff.
Over the last few of months we’ve subsequently had a lot of conversations — not just about the wheelset he sent me, but about BladeX itself, where the company has been for the last few years, the wheel market generally, hubs, spokes, rim design, CFD, lateral stiffness, testing and some of the products he’s looking at developing in the future.

One of the things I initially asked him was why, considering BladeX has apparently been in the industry for quite a long time, there was relatively little recent visibility internationally. His explanation was that much of their business over recent years has been OEM/B2B, manufacturing and supplying products for other companies, rather than concentrating on building BladeX as a consumer-facing international brand. He’s now looking to change that and put more focus back into BladeX itself.

It’s also worth addressing something that’s already been mentioned in these threads: the current rim profile isn’t being presented to me as a proprietary BladeX design. Similar/identical profiles are available elsewhere, and I actually know somebody riding what appears to be the same profile from another wheel company. I’ve discussed that directly with Jason and he doesn’t deny it.

His current philosophy is essentially that there’s nothing inherently wrong with using a proven open-mould rim, an existing hub and available spokes if the combination produces a good wheel at the intended price point. At the same time, he’s now working on proprietary rim development and has been showing me some of his CFD work and ideas around rim profiles, side force, crosswind behaviour, rim stiffness etc.

We’ve also had quite a lot of discussion about eventually treating a wheel as an integrated system — rim layup and stiffness, hub flange geometry and spacing, spoke angle, spoke dimensions, lacing pattern and tension — rather than simply buying a rim, hub and spokes independently and assembling them. That’s obviously future development, though, not something I’m claiming about the wheelset I’m currently riding.

The wheelset and the initial problem

The wheelset Jason sent me uses the very narrow/lightweight 3.1 mm carbon spokes, which was one of the things I was particularly interested in testing because there’s been plenty of discussion on Weight Weenies forum about these newer skinny carbon spokes and whether the continued reduction in spoke dimensions and spoke counts compromises lateral stiffness as many of the superlight weight wheels on the market are no using these kind of spokes

Unfortunately, the wheels didn’t have a completely straightforward start.

When I initially mounted them, I found play in the wheels when they were fitted and clamped into the bike. We spent quite a bit of time going backwards and forwards trying to establish exactly where it was coming from.

Speaking with Jason his opinion was that it maybe the bearing so immediately he  sent a complete set of replacement bearings to the UK by FedEx and offered to cover all associated costs.

Once the bearings arrived, I took the wheels to a local bike shop and had all of the bearings replaced, including the freehub bearings. The labour which, which BladeX reimbursed.

That appears to have completely solved the play.

Riding them

Since getting the bearing problem sorted, I’ve now put approximately 150 km on the wheels.

I’m running Goodyear Eagle F1R tube-type tyres 32mm and these WAM on these is 34mm

The first substantial outing was the Cotswold Classic on Saturday, which wasn’t exactly a gentle first ride. There are some pretty tough sections with gradients reaching around 17%, so there was plenty of climbing and out-of-the-saddle loading.

I then used them again yesterday on a faster group ride.

I’m around 78-80 kg, and one of the things I’ve deliberately been interested in is lateral stiffness because of those 3.1 mm spokes.

So far, I personally haven’t noticed a stiffness problem with this particular wheelset.

That’s relevant because I do own another carbon-spoke wheelset where I can induce slight front rotor rub during harder out-of-the-saddle efforts. That particular wheel uses a 2:1 front lacing arrangement with similarly lightweight carbon spokes. So I do have something to compare the BladeX wheels against.

With these, I’ve not noticed obvious rotor rub, unusual movement or anything else that has made me question the lateral stiffness so far.

I’m not claiming that 150 km proves anything about long-term durability, and I’m certainly not claiming I’ve scientifically measured the stiffness. This is simply my experience riding them.

There’s a lot of discussion about wheel stiffness where somebody grabs a wheel and pulls it towards the chainstay and decides whether it’s stiff. Personally, I’m much more interested in what happens when I’m actually riding the bike — climbing out of the saddle, sprinting, cornering and putting load through the front wheel.

At around 80 kg, after the Cotswold Classic and a faster group ride, I haven’t personally found the 3.1 mm spokes problematic on this particular wheel build.

I’ll keep putting mileage on them and update this thread rather than calling this a review after 150 km. I’m particularly interested in seeing whether spoke tension remains stable, whether anything changes as the mileage builds, and how the wheels behave during harder sprinting and fast group riding.

So at the moment I’d describe it as a problematic start caused by the hub/bearing issue, followed by a positive first 150 km once that was resolved.

And since the wheels were supplied to me, I think it’s important to be completely transparent about both sides of that story. The bearing problem shouldn’t have happened, but equally I can’t fault the way Jason personally dealt with it.

I’ll keep adding updates here as I get more distance on them.



Wheels Specs:
https://bladexcycle.com/product/road-ultra-60d/

Rim

Depth   60mm
Set Weight   1234g±30g (1194g Actual)
Wheel Weight   F: 566±15g/R: 668±15g
System Weight Limit   100kgs
Optimized Tire Size   30-32mm
Compatible Tire Size   30-50mm
Max Tire Pressure   70 PSI(4.8 BAR)


Rim Depth   60mm
Set Weight   1234g±30g
Wheel Weight   F: 566±15g/R: 668±15g
System Weight Limit   100kgs
Optimized Tire Size   30-32mm
Compatible Tire Size   30-50mm
Max Tire Pressure   70 PSI(4.8 BAR)
Rim Weight   440g
Internal Width   25mm
External Width Bead 32mm
External Width   34mm
Hole Count   20
Material   Torayca™ T700 + Torayca™ T1000
Rim Finish    UD/Clear Coat
Tubeless Compatibility   Yes

Hubs

Model   Ultra(Carbon Spoke)
Count   20/20
Weight   270g(F: 84g/R: 186g)
Bearings   F: 2 S&S Ceramic Sealed/R: 4 S&S Ceramic Sealed (These were swapped for steel)
Freehub system   Rachet 54T (Was told last night wheels noisy as fuck  ;D so may need some grease  ;D)

Spokes

Model   Ultra 1.8g
Weight   1.8g(Nipple Excluded generally 2.1g)


frewster

Thanks for the report. I'm curious about how the play in the hubs could possibly be missed during wheel building. Seems like it would be near impossible to properly true the wheels with such play. How true were they after the bearings were replaced?

Sander2177

Thanks for the report. I'm curious about how the play in the hubs could possibly be missed during wheel building. Seems like it would be near impossible to properly true the wheels with such play. How true were they after the bearings were replaced?

It was around 2mm of movement at the rim, so we’re not talking about the wheel moving around massively.

The way I noticed it was once the wheels were fully mounted on the bike. I always grab the top of the wheel and physically rock it from side to side to check for any play. That’s when I could feel it.

If the wheel was simply mounted in a truing stand and spun to check radial/lateral true, I honestly don’t know whether you’d notice it. Even when moving the wheel around off the bike, the play wasn’t particularly obvious unless you were specifically looking for it.

I’m also not sure how reasonable it would be to expect a wheel builder to check that their hub supplier had fitted a bearing with the wrong internal diameter by 1mm. The explanation I was subsequently given was that a 14mm ID bearing had been fitted where the hub required a 15mm ID bearing.

Once the correct bearings were fitted, the play disappeared and the wheels remained true, so thankfully it was a relatively straightforward fix.

Obviously, if I’d purchased the wheels myself I’d have approached it in much the same way. A problem isn’t ideal, but if the company identifies it, supplies the correct parts and covers the cost of putting it right, I’m personally fairly reasonable about these things. Jason had also made it clear that if the bearings didn’t resolve it, the wheels would have needed to go back.

Thankfully that wasn’t necessary and the replacement bearings solved it.

antoinesbikes

I'd be interested if you could make some wide-shoulder gravel rims. Specifically with 26-27mm internal, 43-46mm external. This would provide a smooth transition for 44c+ gravel tires, similar to the NEWMEN or DUKE racing wheels, as well as ROVAL.