Method for producing a cast vehicle wheel

A method of manufacturing a cast vehicle wheel including at least one wheel trim cover attached thereto, wherein the method comprises the steps of:

• (a) providing a wheel mold assembly having a cavity defining a shape of the wheel;
• (b) providing a removable first tool insert adapted to be installed into the mold assembly, wherein the first tool insert includes a mounting feature that communicates with the cavity of the mold assembly to form a mating feature in the wheel when the wheel is cast;
• (c) installing the first tool insert into the mold cavity;
• (d) casting the wheel by introducing a casting material into the cavity of the mold assembly, thereby forming the mating feature in the wheel;
• (e) removing the wheel from the mold assembly;
• (f) providing at least one wheel trim cover adapted to be attached to the wheel at the mating feature of the wheel via a coupler formed in the wheel trim cover such that a relative position of the coupler and the mating feature positions the wheel trim cover relative to the wheel in a first predetermined position;
• (g) optionally attaching the wheel trim cover onto the wheel at a location of the coupler and the mating feature;
• (h) evaluating positional dimensions of the mating feature of the wheel relative to the coupler of the wheel trim cover to determine a positional accuracy of the mounting feature of the first tool insert;
• (i) subsequent to step (h), providing a second tool insert having a second mounting feature dimensionally different from the mounting feature of the first tool insert which provides improved positional accuracy of the wheel trim cover relative to the wheel in a second predetermined position;
• (j) replacing the first tool insert from the mold cavity and installing the second tool insert into the mold assembly;
• (k) casting a second wheel by introducing a casting material into the cavity of the mold assembly;
• and
• (l) attaching the wheel trim cover onto the second wheel at the location of the coupler and the second mating feature.