ONE for ALL

Spline® ONE

In spring 2013 the SPLINE® ONE wheels revolutionized the world of alloy MTB wheels. But a lot has happened in the last three years. The world of mountain biking has grown much more diverse. More standards have popped up, the field of applications has diversified and even the rider expectations have increased. The simple combination of light and durable is no longer enough. Today’s keywords are: Plus sizes, wider tires, wider rims and new hub standards. DT Swiss is prepared for this new era. Ready with the new SPLINE® ONE wheels!


ONE for ALL

The new generation SPLINE® ONE takes it one step further. It is the perfect wheel for every biker, featuring the most advanced technologies and the highest level of quality for each application. These SPLINE® ONE wheels set new benchmarks for alloy MTB wheels.

XR 1501 SPLINE ONE

The new 22.5 mm wide Cross Country specific XR 1501 SPLINE® ONE comes with all the advancements of a modern Cross Country rim, only at 2.5 mm more width – providing more air volume for the same size tire which creates more traction and comfort. The asymmetric rim further improves spoke angles, making the wheel even stiffer, more precise handling and more responsive.

The Cross Country wheels:

XR 1501 Spline<sup>®</sup> ONE 27.5 / 22.5 mm

XR 1501 Spline® ONE 27.5 / 22.5 mm

Cross Country Wheel

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XR 1501 Spline<sup>®</sup> ONE 29 / 22.5 mm

XR 1501 Spline® ONE 29 / 22.5 mm

Cross Country Wheel

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XM 1501 SPLINE ONE

In addition to the current 22.5 mm inner width All Mountain rim, we offer the new XM 1501 SPLINE® ONE model in a number of additional widths: 25 mm, 30 mm, 35 mm and even a  40 mm. The XM 1501 SPLINE® ONE is the perfect combination of light weight, multiple rim widths and reliability.  With a total of five rim widths to choose from for only one category of wheels we now offer the perfect solution for each individual riding style and bike, be it standard sized tires or the wider yet „Plus-Size“ tires.

The All Mountain wheels:

XM 1501 Spline<sup>®</sup> ONE 27.5 / 22.5 mm

XM 1501 Spline® ONE 27.5 / 22.5 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 29 / 22.5 mm

XM 1501 Spline® ONE 29 / 22.5 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 27.5 / 25 mm

XM 1501 Spline® ONE 27.5 / 25 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 29 / 25 mm

XM 1501 Spline® ONE 29 / 25 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 27.5 / 30 mm

XM 1501 Spline® ONE 27.5 / 30 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 29 / 30 mm

XM 1501 Spline® ONE 29 / 30 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 27.5 / 35 mm

XM 1501 Spline® ONE 27.5 / 35 mm

All Mountain Wheel

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XM 1501 Spline<sup>®</sup> ONE 27.5 / 40 mm

XM 1501 Spline® ONE 27.5 / 40 mm

All Mountain Wheel

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EX 1501 SPLINE ONE

The hard hitting Enduro version, the EX 1501 SPLINE® ONE, is coming in two widths – in 25 mm and 30 mm. It combines all the tech features of the current model with the newest technologies to create the perfect set of wheels for Enduro riding and racing. There is a reason, why Jared Graves  & Richie Rude took the overall win of the EWS in two consecutive years on EX 1501 SPLINE® ONE wheels.

The Enduro wheels:

 
New way of riding

Traction, comfort and efficiency

Over the recent years the combination of tire and rim has shifted more and more into focus. By matching MTB tires with (wider) rims, it is possible to increase grip and traction immensely. Normal sized tires up to 2.4” now span a wide range of suitable rim widths from the traditional 22.5 mm all the way to a rather progressive 30 mm, while 2.8“ to 3.0“ Plus-sized tires can only make full use of their potential on equally wider rims – starting from 30 mm all the way to 40 mm internal width.

Excessive casing flex is greatly reduced by wider rims, leading to a much more precise and defined handling – even when riding at very low tire pressures. The positive result: Through low tire pressures the tire is able to „hug“ the ground more closely. Rolling over rocks, roots, gravel and mud is getting much easier and „shredding trails“ is simply more enjoyable.
At the same time the low tire pressure also increases comfort, without compromising too much in terms of rolling resistance. All in all this results in a better and smoother ride, saving energy where possible. Trails and line choices, which before had been challenging and only ridable in mint conditions, now can be tackled with full confidence - anytime.

Traction

Everyone knows: Getting your power to the ground and turning it into propulsion is something one can’t get enough of. The better the traction, the better the ride. But traction is easily challenged by mixed or loose grounds or when slippery roots or wet rocks are involved. And this is where wide tires on wide rims excel. When ridden at low tire pressures and tubeless, the level of traction is simply unbelievable. All of a sudden trail conditions become irrelevant – wet or dry – and roots or rocks loose their terror.

Comfort

Comfort is not only for wimps! This is a lesson we have already learnt in the beginning days of our sport, and one that is still valid in our modern times despite bike suspension being more sensitive and efficient than ever. None of us care to feel every hit from the ground transmitted unfiltered and undampened all the way to our spines, do we? A comfort enhancing bike setup saves energy, keeps you fit and focused longer and provides more control when it really matters. Until now comfort has almost exclusively been attributed to the bike’s suspension, but more and more we see wheels and tires shift into the limelight. With the new generation of rims, be it 30 mm, 35 mm or even 40 mm, allowing low tire pressures, DT Swiss picks up the ball – giving the rider the options to individually match tires and wheels to really satisfy every need for comfort on a whole new level.
 

Efficiency

Efficiency is the ratio between energy input and outcome. Put in a nutshell and applied to our example at hand this means: The more traction and the better the comfort – the higher the resulting efficiency. It is every biker’s goal to see as much of the energy invested being transferred into forward momentum, to be as efficient as possible and waste as little energy as possible. But it would be plain wrong to only consider traction and comfort when talking about efficiency. To ride efficiently also means the overall energy output should be kept minimal, which brings us to another point to be considered: The weight. Only if our wheels are wide and light they meet our requirements of true efficiency.
Making of

Making of

The entire production process starting from the development of the best alloy, through rim extrusion or our continuous chain of quality control, all the way to the finished wheel – everything at DT Swiss is done according to the highest quality standards. Every step during productions is meticulously refined and plays its role in achieving the best possible quality overall. DT Swiss has built up decades of first hand experience in optimizing all those processes. Throughout the entire chain of production we work in very specialized departments and cooperate only with the best long term partners in the industry.

 
Alloy

Alloy

At the beginning of every SPLINE® ONE rim stands the specific alloy, which greatly influences the rims’ properties. Each rim has to cope well with extreme stresses, be as light as possible and still endure years of hard trail use without any issues. Those high demands can only be met with a very advanced and specific alloy. This alloy is the result of our cooperation with long term development partners and suppliers and extensive R&D efforts. In the process raw aluminum is enhanced by further elements such as silicon, manganese and magnesium.
Blank

Blank

After cooling, the refined alloy gets heated a second time – this time around 400°C – in a special oven. At that temperature it becomes viscous again (much like honey) and now can be forced through a gigantic metal extrusion press. This step requires much caution and a very precisely tuned feeding/extrusion speed. The tools employed here need to be manufactured to the utmost precision because even the tiniest deviation will have an enormous effect on the future rim’s integrity. In this process the alloy is extruded with enormous force pressing the viscous metal through the tooling to achieve the desired strength.
Geometry

Geometry

Prior to this the precise geometry of the rim profile and the distribution of wall thicknesses have been defined according to our years of experience in rim manufacturing and optimized via FEM simulation. By the means of FEM (Finite-Element-Method) we can simulate physical processes like evaluating forces on deformable objects or complex structures (such as a rim), which by other means would be impossible or very difficult to attain.

Turning alloy profiles into high-tech rims

Only by combining the ideal alloy and an optimal rim design it is possible to create the perfect rim. A faulty rim design cannot withstand long term trail (ab)use even if made of the best possible alloy. Just like a perfect rim design can never unfold its potential when executed with an inferior alloy.
Before the actual rim production starts all material goes trough very stringent continuous quality controls, such as verifying the correct alloy composition, measuring the hardness of the billet rim and its yield strength.
Bending

Bending

The first step is to bend the still straight rim profiles into their ring shape – each strand turned into a full three circular rings. The bending process requires a lot of experience, a very precise adjustment of the bending rolls and constant inspection because it sets the base for meeting our tight tolerances in diameter, alignment and roundness.
Cutting process

Cutting process

After bending the raw profiles into the triple circles, the structure is then cut into what is to become one circular rim. This sounds simple but takes a very careful and precise cutting process, which has to be monitored constantly. The individual rings are then pneumatically cleaned from cuttings, before being checked for the exact diameter and alignment once again.
Welding

Welding

Then, just prior to welding, small fitting pieces are inserted into the open ends of the rim and fixed there. Their purpose is to support the thin walled rim structure from the inside during the welding process and keep it from collapsing. The actual welding of the joint, performed by a robot takes only 3 seconds – with specific fixtures for every rim design and diameter.
Weld seam

Weld seam

After this machine controlled step some more manual labor is necessary. The weld itself is inspected, then ground off and polished to take off all excess material and create a perfectly even surface. Only when the rim is 100% clean and re-checked it can pass on to the next step.
Bead Blasting

Bead Blasting

Before spoke holes are being drilled, each rim is bead blasted – a process where the alloy surface is bombarded with thousands of tiny round metal balls. The desired effect of condensing and hardening the alloy’s surface takes a precise approach of pressure, distance between the surface and machine and time of exposure. By the inherent compressive stresses through the metal balls onto the surface, fracture resistance and long term durability are increased. In addition this process creates a very even and high-quality surface, which when anodized becomes a very durable, corrosion free and good looking surface.
Drilling spoke holes

Drilling spoke holes

Next we drill the spoke holes, which happens fully automatic in a special machine of our own design. During the actual drilling the tools are sprayed by specific additive for cooling and lubrication to help reduce friction and heat build up. This prevents unwanted local heat spots, keeps tolerances tight and conserves the surface integrity.
Anodizing

Anodizing

The final step in the rim production is the anodizing, which turn our rims into their typical matte black color. By a chemical process this creates an oxidic protective coating by turning the upper atomic layers of the alloy into an oxide. This final manufacturing step guarantees the desired hardness of the rim’s surface plus an exceptional corrosion resistance without any additional weight.
Finishing

Finishing

The finishing touches are then done by manually applying the extremely durable “Waterslide“ decals on the rims, which then are „burnt in“ with moderate heat. Of course those decals are precisely placed on the rim by hand to create the high-quality finish we are known for.
Testing

Testing

To meet our high standards and provide maximum performance the SPLINE® ONE wheels undergo extensive testing – just like any other DT Swiss product. These tests are performed in-house in our headquarters in Biel, Switzerland, by our experienced engineers and resemble the final step in the development process. Before being cleared for production each new SPLINE® ONE model has to pass a number of elaborate tests, which we will introduce in the following.


Roller drum test

On the roller drum test rig wheels are permanently tested for their long-term durability: While being subjected to driving forces and side loads the wheels are also confronted with different obstacles – with one test run compiling millions of simulated hits. This way we make sure the wheels will withstand years of rough trail rides in real life.

Drive torque test

During the drive torque test, shown in the following video, we simulate how the wheel reacts to torque input by the rider: After all, the peak torque affecting a MTB hub are higher than the ones working in an average mid-class automotive.
At DT Swiss we developed our own drive torque test where we statically induce maximum peak loads on the wheel trough the freewheel. Directly following we check the wheels’ long-term integrity by a dynamic test. This way we make sure every part of the wheel will last and last under maximum rider input and aggressive out-of-the saddle cranking.

Impact test

The following video shows the so-called impact test. The wheel is fixed in a jig where a rubber hammer strikes the rim with a predefined impact force. This way we test for maximum loads and impacts on the wheel like they happen out on the trail, e.g. during jumps with landings to the flat or when shredding rock sections where a very localized hard rim strike is likely.
 

Test passed!

Only when a wheel has passed all of the above mentioned tests, we give our Go for serial production. Besides lab testing our new SPLINE® ONE wheels also have seen countless hours real life trail action – be it on the near legendary daily lunch rides of our engineers or under our many test riders.
Technology

SPLINE ONE TECHNOLOGY

Wide, lightweight rims, a simple tubeless setup and super-light, straight-pull hubs offer bikers greater traction, comfort and efficiency on the trail. Our engineers developed numerous advanced details in this new wheel line-up. Such as a specific bead blasting method for surface hardening and a very gentle anodizing process producing an unsurpassed surface durability at no additional weight. This way even our extra wide versions of the SPLINE® ONE family of wheels are more than light enough to not hold you back when tackling even epic climbs.

Rim profile – wide and light

Rim profile – wide and light

Besides the revised designs and new widths the SPLINE® ONE rims are the result of extensive expertise and state-of-the-art computer simulations.
Immaculate surface

Immaculate surface

With their low weight all rims are welded in a proprietary process, which together with our post-weld machining leave nothing but a perfectly immaculate surface. The super thin and extremely durable waterslide decals provide a high-end professional finish
Tubeless ready

Tubeless ready

All SPLINE® ONE wheels are developed to be run tubeless with a specific sealing rim tape. By optimizing the rim bed design, tire mounting is very easy while the bead seat is bomb proof and secure even at low pressures. There is no faster and easier way to go tubeless!
PHR – Pro Head Reinforcement System

PHR – Pro Head Reinforcement System

The PHR system increases the load-bearing surface of the nipples on the rim and reduces localized stresses. Peak loads are reduced allowing us to built the rim even lighter. The washer’s shape also acts as a ball joint and automatically aligns the specific DT Squorx Pro Head® ball head nipples with the spoke further, reducing the risk of spoke failure or rim cracking.
DT competition spokes

DT competition spokes

For low weight and maximum durability, our new SPLINE® ONE family of wheels come with high-quality DT competition® spokes. Our own DT competition® spokes are manufactured in our own patented cold forging process which makes them very light and extraordinarily strong. The spoke diameter is manipulated by oscillating hammers circling the raw wire and compacting its crystalline structure. The butted part of the spoke provides some elasticity and reduces the overall weight, while the full size head and thread keep strength high – the ideal spoke for the SPLINE® ONE rider’s demands.
Machined lightweight hub shells

Machined lightweight hub shells

In the SPLINE® ONE line of wheels we use the lightest alloy hub shells ever produced by DT Swiss. By extensive milling and machining we leave material only where it really is needed. The high-quality two-tone anodized finish underlines the status of this top-end product.
Modular hub design

Modular hub design

The modular DT Swiss hub system with easy to change end caps allows for a tool-free change of axle and rotor standards and makes servicing a very fast procedure.
DT Swiss Ratchet System

DT Swiss Ratchet System

Our patented DT Swiss Ratchet System is already synonymous for reliability. This reputation is owed by he highest level of precision in production as well as the simultaneous engagement of all ratchet teeth. The SPLINE® ONE family of wheels comes standard with the 36-point engagement, giving the rider instant power transfer every 10° of the freewheel.
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