In the pursuit of the perfect bicycle wheel, Carbon Endurance Components (CEC) developed a range of Innegra-reinforced carbon composite rims for mountain and gravel bikes. These rims combine light weight, strength, and vibration damping to deliver a smooth and responsive ride.
During the development process, CEC discovered an innovative approach from Berd, a company redefining the fundamental structure of the modern spoked wheel. Together, we explored how advanced materials and smart engineering could change the way wheels are designed and built.
Many people assume that a bicycle wheel is supported from the ground up, that the lower spokes carry the rider’s weight. In reality, a wheel works the opposite way.
The upper spokes are under tension, effectively suspending the hub inside the rim. This tension network distributes forces evenly and keeps the wheel light, strong, and resilient. The challenge in wheel design is managing this tension precisely and evenly, especially when experimenting with new materials.
Berd replaced traditional steel spokes with a flexible textile spoke made from Dyneema. Commonly used elsewhere in the outdoor and health and safety sectors for light weight high tensile products, such as slings, climbing ropes ropes and harnesses. Dyneema is a ultra high molecular weight polyethylene, in this case woven into a braid. Think of it as a piece of string.
These braided spokes offer several advantages:
The result is a wheel that feels lighter and more compliant, without sacrificing strength or stiffness. It’s a clever rethink of a century-old design principle.
When we tested an early prototype of the Berd wheelset, the ride quality was exceptional. Light, Fast, comfortable, and responsive. However the wheel-building process was difficult and slow whilst also revealing several mechanical challenges.
Because one end of each spoke was fixed into a standard hub using a loop and catch (a little like a Chinese finger trap) and the other tensioned with a threaded bar, the rope would twist under load. This caused uneven tension across the wheel and, over time, the spokes were self-loosening during use.
We also observed premature wear where the textile cord met the spoke nipple. These small but critical issues limited the wheel’s long-term durability and consistency in performance.
To resolve these issues, we re-engineered the hub interface.
Our new design introduced a threaded nipple at the hub end, paired with standard cup washers and spoke nipples at the rim end.
This configuration allows direct, linear tension from hub to rim, with opposite threads at each end. The benefits were immediate:
The redesigned system behaves like a straight-pull spoke wheel, while retaining all the vibration-damping and weight-saving benefits of Berd’s textile technology.
Our collaboration with Carbon Endurance Components and Berd demonstrates how innovation happens when advanced materials meet practical mechanical design.
By addressing small but critical assembly challenges, we helped create a lighter, more durable, and easier-to-service wheel system. One that redefines what’s possible in modern wheel construction.
At Mouse Design, we specialise in product design, prototyping, and engineering for clients who push boundaries. Whether you’re exploring new materials, structural concepts, or manufacturing challenges, we can help turn your ideas into real, functional products.
Get in touch with us to start your next innovation project.
