Development and series production of one-piece carbon fibre wheels for OEMs, motorsport and aviation
Carbon Revolution
Waurn Ponds (Geelong), AustraliaNew on Amplifa
About Carbon Revolution
Carbon Revolution is a global technology company and Tier-1 OEM supplier based in the Geelong Technology Precinct in Waurn Ponds (Geelong), Australia. Founded in 2007, the company designs and manufactures one-piece wheels made of carbon fibre composite that are up to 40–50% lighter than comparable aluminium wheels. Production takes place in its own purpose-built series production facility using High-Pressure-Resin-Transfer-Molding (HP-RTM) and an automated production line (Mega-Line) employing Industry 4.0 technology. Every wheel undergoes more than 160 in-process measurements and inspections, including 3D CT scan, helium leak test as well as tolerance and balance checks. Carbon Revolution has won 18 programmes with six global OEMs and sold over 100,000 wheels, including to Ford, Ferrari, General Motors, Jaguar Land Rover, Renault and Lamborghini. The company employs around 350 staff, primarily in Australia as well as in North America and Europe.
- Site
- VIC 3216 Waurn Ponds, Australia
- Processes
- Carbon Fibre Wheel Manufacturing (one-piece carbon fibre composite wheels), High Pressure Resin Transfer Molding (HP-RTM, resin injection at 50x atmospheric pressure), Wheel Testing (impact tests according to SAE/OEM, BIAX fatigue test, on-vehicle testing), 3D CT Scan (quality inspection, 12,000 images per wheel), Helium Leak Test, Tolerance and Balance Inspection, Product engineering (composite design, FEA, virtual product development), Manufacturing of carbon fibre wheels in series quality
- Materials
- Carbon fibre (carbon fibre composite, anisotropic material), Resin (resin for injection), Aluminium (reference material for comparison, not processed in-house), Carbon fibre composite (Carbon Fibre Composite), Resin (HP-RTM injection), Finite element analysis (virtual product development)
- Certificates
- ISO 9001:2015 (AS/NZS ISO 9001), IATF 16949:2016 (1st Edition), Ford Q1 Certification, ISO 9001:2015 (AS/NZS), IATF 16949:2016, Ford Q1
- Founded
- 2007
- Employees
- approx. 350
- Industries
- Automotive industry (OEM Tier 1), Performance and premium vehicles, Motorsport, Electromobility (EV), Aftermarket, Aerospace
- 01
Product engineering (CAD, FEA, digital twin)
- 02
Fibre layout and preform manufacturing
- 03
HP-RTM resin injection (50x atmospheric pressure)
- 04
Demoulding and curing
- 05
3D CT scan, helium leak test, tolerance and balance inspection
- 06
Assembly and delivery
Materials and Processes
Carbon fibre composite (Carbon Fibre Composite)
Anisotropic composite material with high specific stiffness; enables weight reduction of up to 40–50% compared with aluminium.
Resin (HP-RTM injection)
Injected into the fibre layout at 50x atmospheric pressure and forms the matrix of the composite component.
Finite element analysis (virtual product development)
Simulates driving dynamics loads such as cornering and kerb contact to optimise the wheel design before tooling is manufactured.
Sites
Waurn Ponds (Geelong)
AUManufacturing, design and administration (Geelong Technology Precinct)
- Lot size
- High-volume series (OEM programmes)
- Materials
- Carbon fibre composite, resin
- HP-RTM system
- Mega-Line (automated production line, validated by digital twin)
- BIAX test rig
- 3D CT scanner
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Carbon Fibre Wheel Manufacturing (one-piece carbon fibre composite wheels)Plastics | – | – | – | – | Carbon fibre/carbon fibre composite (carbon fibre composite), Resin (resin injection) |
| High Pressure Resin Transfer Molding (HP-RTM, resin injection at 50x atmospheric pressure)Plastics | – | – | – | – | Carbon fibre, Resin |
| Engineering | – | – | – | – | Carbon fibre composite |
| Wheel Testing (impact tests according to SAE/OEM, BIAX fatigue test, on-vehicle testing)Testing | – | – | – | – | Carbon fibre composite |
| 3D CT Scan (quality inspection, 12,000 images per wheel)Testing | – | – | – | – | – |
| Helium Leak TestTesting | – | – | – | – | – |
| Tolerance and Balance InspectionTesting | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| High Pressure Resin Transfer Molding (HP-RTM) system | – | – | – | – | Waurn Ponds VIC, Australia |
| Mega-Line (automated production line, digital twin validated) | – | 1 | – | – | Waurn Ponds VIC, Australia |
| BIAX testing fixture (wheel test rig) | – | – | – | – | Waurn Ponds VIC, Australia |
| 3D CT Scanner | – | – | – | – | Waurn Ponds VIC, Australia |
Additional services
Reference customers
Quality
Carbon Revolution operates an integrated management system according to AS/NZS ISO 9001:2015 and IATF 16949 and is Ford Q1 certified. Every wheel undergoes more than 160 in-process inspections, including 3D CT scan (12,000 images per wheel), helium leak test as well as tolerance and balance inspection; additionally impact tests according to SAE/OEM, BIAX fatigue tests and on-vehicle testing.
| Evidence | Waurn Ponds (Geelong) |
|---|---|
| ISO 9001:2015 (AS/NZS) | |
| IATF 16949:2016 | |
| Ford Q1 |
History
- 2007
Company founded with the aim of developing disruptive efficiency technology for vehicles
- 2021
Commissioning of the first Mega-Line to increase production capacity and efficiency (commissioning 2021–22)
- 2023
Mega-Line has been producing series wheels since early 2023; site receives Ford Q1 certification
- 2024
Lamborghini presents the Temerario with Carbon Revolution wheels
- 2025
Delivery of carbon fibre wheels for the Lamborghini Temerario
- 2026
Exit from voluntary administration as a newly privatised company after recapitalisation; awarded the Composites Australia Engineering Team Excellence Award