Composite wheel assembly and method of manufacturing

A method of forming a wheel assembly, the method comprising the steps of:

• providing a contoured mold for a wheel, wherein the mold includes an axially inner end an axially outer end and a radially outer surface and a drop well region having an outer diameter that is reduced relative to the radially outer surface;
• advancing at least one first tube preform having one or more layers of composite material over the radially outer surface and the drop well region;
• inserting the at least one first tube preform inward into the drop well region;
• placing a plurality of spaced apart attachment inserts into the drop well region over the at least one first tube preform wherein the attachment inserts are spaced apart at a predetermined and fixed circumferential spacing;
• advancing at least one second layer of composite material over the at least one first tube preform and the plurality of spaced apart attachment inserts;
• curing the at least one first tube preform and the at least one second layers of composite material to form a wheel rim;
• and
• retaining the plurality of spaced apart attachment inserts between the at least one first tube preform and the at least one second layers of composite material.

A method of producing a wheel preform, the method comprising the steps of:

• creating a substantially straight wall tube preform having one or more layers of composite material;
• providing a contoured mold for a wheel rim having a radially outer surface and a drop well region having an outer diameter that is reduced relative to the radially outer surface;
• advancing the tube preform over at least a portion of the contoured mold;
• draping the tube preform to a contoured shape on the contoured mold and into the drop well region;
• and
• placing a plurality of spaced apart attachment inserts into the drop well region, wherein the attachment inserts are spaced apart circumferentially at a predetermined fixed distance relative to each other.