It wasn’t all that long ago that carbon-fiber wheels were exclusive to million-dollar Koenigseggs->ke43 and concepts cars,->ke169 and then the sub-$70,000 2016 Ford Shelby Mustang GT350R came along with its seven-spoke carbon-fiber wheels and democratized them for all.

It’s no gimmick either. At just 18 pounds each, the GT350R’s wheels weigh almost half that of an equivalent aluminum wheel, which represents a net savings of about 60 pounds of un-sprung weight. It’s such a leap forward that Ford->ke31 engineers had to recalibrate the Delphi MagneRide dampers to respond to faster suspension movement. The lighter wheels also reduce rotational inertia, which has huge positive effects on braking and acceleration.

Ford is working with Australian carbon-fiber specialists Carbon Revolution on the GT350R’s wheels, which are the first of their kind to be mass-produced. As such, they have to meet the same standards of strength and durability as wheels that Ford bolts to a Focus->ke440 or F-150.->ke423 As stiff and light as it is, a ding or chip to a carbon-fiber part can compromise its structural integrity. Using a unique resin, Ford has designed its new wheel to be extremely tough. It’s been subjected to the same curb strike, UV, chemical exposure and extreme heat tests as every other wheel Ford sells.

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The weight itself also benefits the wheels’ durability. During a curb strike test, Ford says a test driver had to run the test a second time, because he wasn’t sure the test was done correctly. The wheel’s weight, combined with the MagneRide dampers meant the wheel reacted so fast that it reduced the impact to the point that the tester barely felt it. Impressive.

Ford and Carbon Revolution engineers also used a thermal barrier coating normally used in motorsports and the aerospace industry to insulate the wheels from the heat generated by the Brembo brakes, which can get up to 900 degrees. On top of that, the wheels are coated with gloss-black paint that protects the wheels from road salt and other corrosive chemicals. After the wheels are completed, they’re subjected to a test that includes 61 checks and over 246,000 data points. More than 18,000 X-ray images are taken to ensure wheels with cracks or weak points never make it out of the factory.

Why it matters

The benefits of carbon-fiber wheels are patently obvious, but it remains to be seen if they will eventually become the norm throughout the car industry. The cost of materials, development and production are still rather high, but the fact that the technology has gone from a $1 million-plus Koenigsegg straight to a Mustang->ke428 is a good indication that it’s getting cheaper. As the benefits of carbon wheels continue to outweigh the expense, we should start seeing them on more new cars.

2016 Ford Mustang Shelby GT350R

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