MANUFACTURING

“We are what we repeatedly do. Excellence, then, is not an act, but a habit.”

Design, Engineering, Finite Element Analysis (FEA) & Manufacturing

Design is the foundation of every Rusch wheel. Each wheel is designed and engineered in the USA with a deep passion for automotive culture, combining aggressive aesthetics, lightweight construction, and structural integrity into one complete product.

At Rusch, design is never separated from engineering. While visual impact is critical, every wheel must also meet the demanding technical requirements of real-world performance. Proper brake caliper clearance, suspension clearance, fender fitment, load distribution, and driving dynamics are all carefully considered during the development process.

Every vehicle platform has unique specifications, proportions, and fitment limitations. Through our extensive measuring and fitment development process, each Rusch wheel set is optimized specifically for the individual vehicle application. This allows us to maximize concavity, achieve true flush fitment, and maintain proper functionality without compromising drivability.

Our flagship 3-piece forged wheels are proudly manufactured in California, USA, using premium aerospace-grade materials and advanced CNC machining, delivering a true boutique-level product for high-end builds.

For our monoblock and 2-piece forged series, we work with specialized overseas manufacturing partners because the extra-thick forgings required for our proprietary deep concave profiles are not widely available in the United States. These wheels are produced using the same premium-grade materials, advanced forging technology, and strict engineering standards used in top-tier global wheel manufacturing.

This approach allows us to achieve more aggressive concavity and complex designs while maintaining the same high level of quality, strength, finish consistency, and structural integrity expected from the Rusch brand — while also providing our customers with significantly better overall value compared to traditional fully domestic forged wheel production.

Every Rusch wheel undergoes a rigorous design, engineering, and validation process to ensure the final product meets both aesthetic and performance objectives. From wheel configuration and offsets to finishes and hardware, each set is tailored to the customer’s vehicle and vision.

Using advanced Finite Element Analysis (FEA) software, every wheel design undergoes simulated radial fatigue, cornering fatigue, and impact load testing specific to the intended vehicle application. In addition, Rusch wheel designs are physically tested in accordance with internationally recognized SAE, JWL, VIA, and TÜV standards to ensure safety, durability, and long-term performance under demanding conditions.

Once engineered, each wheel’s CAD model is programmed for machining using computer manufacturing software (CAM). The program, or G-Code, is developed using CAM to guide each machine’s tool paths while ensuring that the final wheel precisely matches what the engineered CAD model intended.

Wheel forgings and machining process.

Quality materials are the basis for a quality result. The wheel forgings, which we use to manufacture Rusch Forged Wheels are made in high tech IATF16949 and ISO9001 cetified full automation process factory with ultrasonic material detector line and 3 presses with extreme pressure of 12000 ton.

After press the forgings pass T6 heat treatment to create a high integrity, multi-directional grain structure. The aluminum remains solid throughout the process as the forging dies press the aluminum into the cylindrical shape of a wheel. The result is a highest strength.

6061-T6 aluminum forgings guarantee the highest quality of forged wheel. The result is a superior foundation guaranteed to last, and a trustworthy, high-performing product which meets the highest standards of our team.

Custom forged wheels USA, Switzerland, Poland, Spain, Finland

CNC Machining

At this stage of production, the forged blank gradually becomes a forged wheel with a designed design. Rusch Wheels factory has 11 CNC machines for the production of forged wheels. Lathes are used to achieve high concentricity of a cylindrical workpiece, milling machines with high rigidity and spindle speed provide a smoother surface.
The use of high-quality CNC machines allows us to achieve the highest tolerances, minimizing defects on the surface of the forgings.

Once the face design is complete, the wheel is rotated 180-degrees for additional milling. The lightening pockets are milled into the back pad of the wheel, with decreasing the weight wherever possible by milling the backside wheel pockets.

After milling and hand prep.

Each section of milled aluminum billet goes through many stages of deburring, hand filing, buffing and polishing before it is ready for coating. A collection of tools allow our craftsmen to file and sculpt each profile to perfection, every edge receives the attention of a few hands before it is prepped for final coating.

Finishing process.

Our team utilizes a combination of liquid paints and powder coating processes. Finishing is the final process that determines the wheel’s appearance. Rusch forged wheels go through coating process in several steps: powder coating + baking + paint coating + baking + powder clear coating + baking. Total 3-coating and 3-baking coating processes. Attention to fine details determines the distinction of Rusch wheels.

We are always focused on the perfect color choice and choose only the top quality powder coating and paint suppliers to offer our customers the supreme product.

Precision requires consistency and consistency requires control, which is why Rusch team meticulously inspects every wheel during every step of the process. Rusch specialists conduct inspections on every wheel to ensure precision before proceeding to the next step.

The quality control team confirms every critical dimension according to detailed engineering schematics. Runout, a measurement of a rotating wheel’s roundness, is the most critical measurement. Rusch Forged wheels are checked to confirm that the runout is within tolerance.

Quality control.

Accuracy requires consistency, and consistency requires control, so the Rusch team carefully checks every disc at every stage of the production process.

The quality control team checks and confirms each measurement in accordance with the tolerance in accordance with international quality standards SAE-J and JWL.