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FEATURES: TOUR OF CALIFORNIA TECH: MAD FIBER ROAD WHEELS
Philip Booth
May 18, 2010
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Heading into the Tour of California Road Bike Action received a cryptic email from Ric Hjertberg saying he had something big in the works for the Tour of California. For those not familiar with Hjertberg, he is the founder of Wheelsmith, Wheel Fanatyk, and previously worked as New Technology Manager for FSA. Ric knows wheels and we were excited to see what he had up his sleeve. Not only did Ric have a new set of full carbon wheels but an entirely new company to show off - Mad Fiber™
Hjertberg is joined in the Seattle based start up by Max Kismarton, chief technologist, and an instructor in aerospace engineering with Kansas University. Kismarton is also an engineer for one of the world’s largest aero¬space firms, with engineering and production responsibility for some of the world’s most innovative aircraft, both commercial and military. Also joining the Mad Fiber team is Russ Riggins, Chief Operating and Financial Officer, with more than 30 years’ experience leading start up companies. Riggins is no stranger to cycling – rather, is an enthusiast and coach. Hjertberg, Kismarton and Riggins set out with a singular goal for the new company: to fully realize the potential of carbon fiber in a bicycle wheel.
Unfortunately, just before the Tour of California Ric injured himself and couldn’t make the trip. Fortunately Russ Riggins and Jasen Thorpe made the trek to Sacramento and gave Road Bike Action an exclusive look at the company’s new wheels.
Mad Fiber Road Wheels
Mad Fiber tubular rims are built from three distinct pieces (two sidewalls and the tire seat). This is different than other carbon wheel manufacturing systems that use bladders and molds to emulate an extruded metal rim. This three-piece design increases control of the manufacturing process, minimizing voids and eliminating the use of excess resin resulting in increased strength and decreased weight. The hubs use carbon fiber shells and flanges, while the rear cassette body is constructed from titanium for lightweight and durability. The cassette body uses a unique cone shaped interface that is bonded to a similar convex carbon structure inside the hub. This design helps resist pedaling torque. To further increase hub stiffness the driveside features an oversized flange that provides a large interface for the spokes. Ceramic bearings will be an option in the future.
 The rear hub / cassette body interface
Next, Mad Fiber went about redesigning the spoke to rim interface. Creating a hole in the rim weakens the rim right at the point where the spokes and nipples apply stress. Mad Fiber’s answer is to bond wide carbon spokes to both the rim walls and the flanges. This eliminates the issue of spoke hole drilling, and it spreads tension loads over a broad area, increasing strength and aiding in aerodynamics while reducing weight.
Without conventional spokes the issue of tensioning the wheel comes into play. To solve this problem the spokes are bonded to the rim walls and hub flanges before the flanges are attached to the hub. This means that their un-tensioned lengths correspond to the distance from the rim to the center of the hub. Then all of the parts are placed in a tool that allows the flanges to be moved to the outside of the hub body – increasing the spoke distance and creating tension. The flanges are then bonded in place, simultaneously tensioning the wheel as the spokes are pulled into a position that requires them to cover a longer distance.
Mad Fiber wheels weigh 1085-grams per pair and meet or exceed industry strength, durability and safety standards. Amazingly the wheels are set to hit the market at only $2500.
Look for a full test of the Mad Fiber road wheels in an upcoming issue of Road Bike Action.
For more info: www.madfiber.com
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