behind the falcon pro

What Is Falcon Pro All About?

It is about making road rims that stand the test of time via a more eco-friendly manufacturing process. Two years ago, this ambitious project kicked off. We streamlined the production line from the very first step: material preparation. Thinner and lighter material allows us to form more layers - rim strength is boosted without weight penalty.

Falcon Pro rims come out of the mold as a finished product, and we named this paintless innovation “BlackTek”. No post-production work is required as the out-of-mold finish is smooth and tough. With the naked eye, you can see through the raw finish to the UD fibers beneath. Every Falcon Pro rim has a special fiber pattern which delivers your wheels a unique look.

The Features

20% Stronger
More Impact Resistant
Highly Scratch-Resistant
More Environmentally Friendly
Optional Lifetime Warranty
Paintless Finish
All Road Use
Optional lightweight “Flyweight” model available

Pro Technologies

What makes Falcon Pro pro?

BKT

Black Tek

IPC

Irregular Profile Cutting

SCL

Stepwise Cross-Link

TLO

Thinner Laminates Orientation-Optimized

SWT

Smooth Wall Technology

ACD

Aviation Class CNC Drills

XFP

X-Flow Profile

BKT

/ Black Tek

Rims featuring BlackTek come out of the molds as a finished product. The factory finish preserves the outer layer of resin and the carbon is never disturbed after the curing cycle is completed. This is the hardest wearing finish we have ever produced.

Photos/Graphics

IPC

/ Irregular Profile Cutting

To ensure the strips of prepreg fit the curves of rims, we carefully stretch the material in length or width to achieve an optimal fit without harming the consistency of the UD fibers (too much force will create a weak point on the rim). For some complex shapes, we have an automated cutting process where the material is cut with the curves, grooves, and hooks of a certain rim model in mind. The results? Fiber layup can be done with more accuracy and efficiency, and the product comes with increased overall strength.

SCL

/ Stepwise Cross-Link

Traditionally, several laminates are piled with the edges aligning to form a layer, with a layer applied across the mold end to end, forming one overlap point per layer. The overlapping area is a bit thicker and heavier than the rest, which could leave the rim unbalanced. We stagger the seams so they never directly overlap another seam. The edges are stepped, or overlapped by 2mm and are unnoticeable once the rim is complete.

TLO

/ Thinner Laminates Orientation-Optimized

We use thinner and lighter materials that allow us to form more laminates per layer, achieving stronger cross-linking reactions. Every laminate is ultra-thin, and the extremely smooth unidirectional (UD) plies create a mechanical performance gain. The thinner material is usually twice as expensive. There are more square meters used in each rim, and the layup takes much longer. The advantage is weight reduction and the ability to fine-tune the characteristics of the rim without sacrificing strength or stiffness.

SWT

/ Smooth Wall Technology

We’ve developed a special air bladder material that follows the inner contours of our rims. Coupled with our three-dimensionally shaped air duct, the inner wall of the rim is smoother, lighter, and without wrinkles. The bladder is removed through the valve hole so no patching is required.

ACD

/ Aviation Class CNC Drills

No tear out! Our Pro rims are drilled with aviation-grade CNC machines specifically designed for drilling through advanced composites. The bits have a unique cutting edge that make extremely clean holes. Each hole is inspected to ensure they are free of burrs. The drilling speed and temperature are adjusted as the bit wears, and the bit is inspected after every 60 holes. Competitors use more common high-speed bits which heat the holes and often leave scorch marks. It is not uncommon to see some delamination in other carbon rims due to their inferior drilling process.

XFP

/ X-Flow Profile

The wave style X-Flow rims feature a reduced aero drag, boosted lateral stiffness, and greater impact resistance, compared to our traditional design road rims. We sent several R and AR counterparts along with the newly designed X-Flow rims for comparison, to a third-party testing institute using Computational Fluid Dynamics (CFD). Based on the samples tested, removing crosswinds from the equation for a fair comparison, the X-Flow rims perform the best.

Photos/Graphics

WARRANTY OPTIONS

Whether you‘re tough on wheels or have never cracked a rim, our new warranty gives you the opportunity to get the coverage you need and avoid overpaying for what you don’t want. Our Falcon Pro line of rims come standard with our Pro 5-year Warranty against manufacturer's defects and, for the first time ever, with the option to upgrade this standard warranty to our Premium Lifetime Warranty.

RIM LIST

5-year or an optional lifetime warranty from the date of purchase.

Model	External Width	Depth	Discipline	Weight (+/-15g)	Price (each)	Explore
AR35 disc	28mm	35mm	Road/CX/Gravel	Standard 410g Flyweight 350g	Standard $239 Flyweight $251	Buy Section View
WR40 disc	32mm	40mm	CX/Gravel	Standard 440g Flyweight 400g	Standard $269 Flyweight $281	Buy Section View
AR45 disc	28mm	45mm	Road/CX/Gravel	Standard 460g Flyweight 380g	Standard $249 Flyweight $261	Buy Section View
WR38 disc	32mm	38mm	CX/Gravel	Standard 440g Flyweight 385g	Standard $239 Flyweight $251	Buy Section View Section View
WR50 disc	32mm	50mm	CX/Gravel	Standard 470g Flyweight 410g	Standard $259 Flyweight $271	Buy Section View Section View
WR35 650b disc	32mm	35mm	CX/Gravel	Standard 370g	Standard $259	Buy Section View Section View
AR55 disc	28mm	55mm	Road/CX/Gravel	Standard 480g Flyweight 420g	Standard $259 Flyweight $271	Buy Section View Section View
AR375 disc	28mm	37.5mm	Road/CX/Gravel	Standard 440g Flyweight 390g	Standard $269 Flyweight $281	Buy Section View
AR465 disc	28mm	46.5mm	Road/CX/Gravel	Standard 460g Flyweight 410g	Standard $279 Flyweight $291	Buy Section View
AR375	28mm	37.5mm	Road/CX/Gravel	Standard 450g Flyweight 410g	Standard $269 Flyweight $281	Buy Section View
AR465	28mm	46.5mm	Road/CX/Gravel	Standard 470g Flyweight 430g	Standard $279 Flyweight $291	Buy Section View

^