Specialisation

Automotive
Wheel Design

Class A surfacing for BMW Group — concept to production
50+
Wheels in production
100+
Designs developed
15
Years with BMW Group
5
Class A loops per project
BMW Group — 15 years
Rolls-Royce — active programme
Alias Studio Tools & ICEM Surf
Full DFM — cast, forged, flow-formed
FEA-verified production geometry
The process

Five loops from sketch
to production tool

01
Design & CAS
Concept development from brief or sketch. CAS surfacing establishes the design intent — proportion, spoke character, face geometry.
02
Class A — Loop 1–2
First Class A passes in Alias or ICEM Surf. Surface continuity, reflection quality, and engineering constraints introduced. BMW internal review.
03
Class A — Loop 3–4
Design refinement and engineering sign-off loops. Mounting face, offset, load paths, undercuts, and tooling access all resolved. FEA check.
FEA verified
04
Supplier handover
Approved data handed to manufacturing supplier. Supplier produces their own CAD interpretation for tooling — quality varies significantly.
05
Final Class A
The hardest loop. Supplier CAD is rebuilt to restore surface quality while preserving all engineering constraints. Production-ready final data.
Most critical
What I know

Every constraint,
already considered

Surface quality
Class A reflection quality across all spoke faces, fillets, and barrel transitions. Every surface meets BMW Group internal review standards — because it has, 50+ times.
Manufacturing constraints
Die pull direction, draft angles, undercut management, tooling access, parting line placement. Cast, forged, and flow-formed process requirements — all handled in the surface, not as an afterthought.
Engineering integration
Mounting face geometry, offset requirements, load path considerations, FEA-informed spoke proportions. Surfaces that pass structural analysis without redesign.
Supplier Class A rebuild
The final loop — rebuilding supplier CAD to production Class A standard while preserving all approved engineering geometry. The most demanding part of the process, and a specialisation in itself.
Design language fluency
15 years inside BMW Group design vocabulary — M Sport, iX, standard range, luxury. Surfaces that feel right for the brand, not just technically correct.
Full programme management
From first sketch brief through five Class A loops to production-ready handover data. Independent delivery with no supervision required — the complete programme, end to end.
Commission a wheel

Need a wheel designed
properly, once?

Concept to production-ready Class A. No back-and-forth on manufacturing feasibility. No surprises at tooling sign-off.

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