When it comes to innovations in mobility, the automotive sector often takes the lead with light commercial, off-highway, recreational vehicles and beyond adapting to the technological advancements that passenger vehicles have brought to the market.

But – as industries seek to enhance their sustainable offering to meet Net Zero targets – more is being done by manufacturers and their trusted supply chain partners to bring the necessary changes to their respective markets.

One of the ways we’re working toward a more innovative and sustainable offering for the caravan sector at Wheel Solutions is through the introduction of flow form wheels.

Traditionally, caravan manufacturers have fit cast alloy wheels to their vehicles as standard. And while this choice has often suited caravan and touring enthusiasts for a number of decades, demands from the industry mean new wheel solutions are now required.

What is flow forming?

Flow form wheels, also known as flow-forged or rotary-forged wheels, involve applying pressure to the inner barrel of a cast wheel blank while in rotation, which results in enhanced tensile strength.

For electric vehicle towing, this offers unparalleled benefits such as a 10-12% reduction in weight and a 12-15% increase in strength compared to traditional cast wheels, which not only enhances fuel efficiency but improves manoeuvrability in tight country roads.

These new alloy wheels created through flow form technology represent a cutting-edge hybrid solution, combining elements of traditional low-pressure die-cast aluminium wheels with the strength of forged wheels.

Through our partnership with Sumec, a globally renowned aluminium wheel manufacturer, we’re proud to have introduced this comprehensive lightweight wheel solution to our caravan manufacturing customers. This partnership will further help the shift from traditional casting to more significant advancements in the touring sector.

So, how do flow form wheels benefit caravans and motorhomes?

Well firstly, thanks to the increased tensile strength of flow form wheels, caravan enthusiasts can benefit from enhanced shock resistance, meaning longer journeys will be smoother when navigating potholes and kerb strikes.

This enhanced strength also means a higher load rating which helps support the weight that modern caravans and motorhomes often carry – making them an ideal choice when towing. With electric vehicles now becoming more popular for towing vehicles in the UK, it’s increasingly important that wheels also move with the times.

Why flow form wheels are better than cast alloy wheels

Flow-formed wheels are the next step in moving from the traditional low-pressure die-cast wheels that, while affordable, don’t provide enough benefit to the modern caravan enthusiast.

From an environmental perspective, flow form technology has revolutionised the manufacturing process of alloy wheels. Not only has this process helped enhance durability and fuel efficiency to help lower carbon emissions, but from a manufacturing process, flow form technology minimises material waste by up to 20%. Not to mention their stunning visual appearance, which can enhance any caravan’s aesthetic.

Cast alloy wheels are also less strong as a flow formed alternative, offering less shock resistance are often prone to bending or cracking when towing heavy loads. The fragility of cast alloy wheels is also apparent after hard use on frequent, long journeys tackling uneven terrain.

Not only this but cast alloy wheels are heavier than flow form wheels, which in turn impacts the performance and handling of any vehicle. The lighter weight of the flow form wheel means vehicles can offer superior fuel efficiency, further enhancing their sustainable credentials.

Bringing superior caravan wheels to the market

At Wheel Solutions, we have been working with some of the caravan industry’s leading suppliers and manufacturers for decades, providing the right wheel and tyre solutions to meet the needs of their customers.

As your wheel supplier, we’re able to guarantee the quality and safety of all of our supplied caravan wheels thanks to our Production Part Approval Process (PPAP). Our automotive-style standards are ensured throughout our internal procedures which has positioned us as a frontrunner for the industry.

We understand that travel and touring are a gratifying element to any caravan and motorhome holiday for your customers, which is why we continue to work closely with the biggest wheel and tyre brands in the world. This not only ensures the industry has access to some of the leading innovations from the mobility sector but also provides a range of eco-conscious systems to ensure the industry can continue on a sustainability journey.

Testament to this is our partnership with Sumec. As a vastly experienced producer of alloy wheels, working with 80% of the automotive sector, Sumec’s TUV-accredited facility and industry-leading accreditations ensure meticulous quality management at every stage of production. The partnership with Wheel Solutions is a statement of the commitment to environmental sustainability and innovation which both our businesses share.

Discover flow form wheels for yourself

As a supplier, Wheel Solutions focuses closely on continuous improvement initiatives to provide the best solutions for its customers, and we’d love to discuss our latest product offering with you.

For more information, get in touch with us today!