Where Spokes & Wheels Are Made - Inside The DT Swiss Factory

Thanks to DT Swiss for inviting us to their factory. All opinions are the presenter's own.
Simon has a very special day at the DT Swiss factory, based in, you guessed it, Switzerland. He gets to understand how spokes are made and how their world famous wheels are tested & built.
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Let us know what you think of Si’s guided tour of the DT Swiss factory in the comments below
Simon gets to see technology that is exclusive to DT Swiss as well as handling a hot spoke, yep, a hot spoke. Some things however, remain a secret close to DT Swiss, there is a reason they’ve been in existence for so long
Wheels are tested for both impact as well as imitation of surfaces to ensure that they are perfect for consumers. Oh, and how about those ratchet freehubs, got to love them.
Strain gauges can be attached to prototype and development wheels so that they can be assessed and refined before going into production, the gauges look very cool.
Simon finally gets to check out where the wheels are built for sponsored riders/teams, he also built a wheel himself here is the video for that gcn.eu/BuildWheel
Photos: © Bettiniphoto / www.bettiniphot... & ©Tim De Waele / www.tdwsport.com
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Leave us a comment below!

[@A.D.D.O.C.D.T]

The Swiss always produce quality.

[@jameswhitfield618]

Very nice. I have been buying DT spokes for 45 years. Still love them. Thanks for a look in the factory.

[@dtswiss]

Thanks James! Highly appreciated.

[@MauricioAlsinaLee]

Guys, this kind of videos are really really entertaining. Keep them coming! And thanks you and DT Swiss for the insight!

[@dtswiss]

Thanks Mauricio. You re welcome.

[@robear7293]

This is a must watch for those who appreciate excellence in bike componentry.

[@dtswiss]

Thx! Highly appreciated.

[@joachimglink9245]

Please more of such videos! This was really great inside into DT Swiss. Thank you!

[@dtswiss]

Thanks Joachim. Great to hear you enjoyed it!

[@noizz]

For the curious - the EX471 in the back is THE famous wheel Aaaron Gwin finished a downhill race in Leogang a couple of years ago. It survived multiple drops, jumps and rock sections.

[@dtswiss]

Yes, thats true.

[@bicyclist2]

As a wheel builder myself I found this to be very cool. Thanks.

[@dtswiss]

thx!

[@adrianwood06]

I have always wondered about how DT Swiss continues to crank out top performance. That ratchet sound is the sound of bliss! Thanks GCN and DT Swiss for sharing!

[@dtswiss]

Thanks Adrian, highly appreciated.

[@Werkzeug-Feinschmecker]

the sound of these former Hügi free-wheels is unmatched :-)

[@robertmuckle2985]

Just bought 2 sets of DT Swiss MTB & Gravel and they were the easiest wheels to set up tubeless I have ever dealt with! And their toolless convertible hubs should have been featured more also. They're so easy to go from boost to non-boost, or TA to QR....or whatever conversion you want. Amazing wheels👍

[@marcovalente1972]

Mad props for the work race balance shirt the production manager is wearing. Love the factory tours.

[@durianriders]

Been using DT Swiss 240 since 2000. Best hubs on the market along with Hope. Ive used everything else and only Shimano comes in 3rd.

[@dtswiss]

Thanks man- highly appreciated. Keep it up!

[@tbrowniscool]

@@dtswiss Where are your hubs made?

[@sdqsdq6274]

@@tbrowniscool isnt it in taiwan ?

[@trentrylan882]

I dont mean to be so offtopic but does anyone know a trick to get back into an instagram account? I somehow forgot my login password. I appreciate any help you can give me!

[@mohammedwells1186]

@Trent Rylan Instablaster =)

[@thyneshgunaselan4043]

The kind of video that's got me replaying it several times. Such a joy to watch. Good job Si and GCN, ya'll need to make more like this. :)

[@jonb77]

Just of interest, the wire DT use is manufactured by Sandvik in Sweden and is superb quality (the best really). All the major European manufacturers use the same wire (Sapim and Alpina). The real challenge for DT is quality control and manufacturing consistency, so as to maintain their reputation, and for which they don't seem to be doing too badly.

[@BC-wj8fx]

Sandvik Sweden is the Swiss of the North, amazing engineering quality. Unfortunately they are increasingly selling stainless from the East of marginal (or even terrible) quality, under their name. Their accuracy of manufacture was above and beyond what was required, and I fear this knowledge will be lost to humanity if we keep focusing on the dollar only. Good to see DT Swiss has survived so long and not trying to compete with bottom end prices.

[@perrymeister898]

Discovery channel, how it's made, gcn edition! Really interesting insight, thanx gcn & dt swiss!

[@dtswiss]

Thanks Perry! Glad to hear you enjoyed it.

[@thegrimpeur]

That dude's t-shirt is solid gold: work-ride balance.

[@phillentz6742]

These "how its made" videos are the best. Si is a pro at them!

[@timdodd3897]

Always loved my Butted DT spokes. Thanks!

[@BigGdh100]

Loving the signed Shaun Palmer t-shirt in the background @ 18 minutes

[@zxtenn]

I have a 2016 Focus Raven max SL with XTR- I upgraded the wheels to XRC 1200 and even upgraded the hub from 36 to 54 tooth hub-- sounds simply beautiful and yes love the XRC 1200 wheels

[@avantxz]

i love these type of manufacturing behind the scenes videos. more please.

[@shaunroach7829]

Just bought a pair of DT Swiss ER 1400 discut !!! Upgraded the rear 240 hub from a 36t ratchet to 54t ratchet!!!

[@matthewkluge5441]

Enjoyed watching the process .

[@dtswiss]

Thanks Matthew!

[@monistefmontesdeleon5238]

9:20 I have seen this happen in the field every day in the back wheel of my husbands bike during a bike touring ride, though not with DT Swiss Spokes but „no name“ spokes. Luckily, we had several spare spokes in our repair kit but in the end we had to get our wheel made again by a bike technician to be able to continue our tour. I think this is the difference between high quality wheels like DT Swiss or Mavic and no name products which often are fitted to bikes to reduce the cost and make them more affordable. In the meanwhile, he got a DT Swiss wheel (fitted with a maxxon bike drive) and has never had such issues again despite the fact, that the wheel is under very high stress towing a heavy children trailer and being fitted with a very strong motor.

[@Leotardoification]

And All of a sudden I feel it's time to service my newly build wheelset with DT spokes and rims

[@fissionchips8840]

A great video..!! Luv to see more.. Keep up the gud work GCN!!

[@Romarides]

Why did you blur the name of the spoke machine? i wanted to buy one to make my own spokes :(

[@glennoc8585]

I have DT double butted on wheels going back 20 years and they still look as new,like day they were laced. In saying that my pilar bladed spokes are looking good after several years. Spokes at the upper end are much for muchness now i don't get the top Secret thing. DT have the name and well cashed individuals will buy their product over any competitors.

[@whothefoxcares]

wheel say: *wrench my nipples!*

[@HermanWillems]

www.amba.de/en/all-in-one-spoke-making-machines

[@yogibear26]

No endorse

[@gerekappo]

@@yogibear26 But they didnt make a good job bluuring the logo hahahhahahha

[@ketogenerreini1690]

I love the DT Swiss Freehub.

[@LTPottenger]

This is amazing stuff, very interesting

[@davetone2106]

Excellent! Great tour!

[@HuguesBonin]

I'm curious about the reason for blurring www.amba.ac logo from machine at 3:07.

[@elidouek5438]

so am i...Its a machine tool, not classified information...

[@elidouek5438]

Plausible, but then it doesn't explain why Zwick, the manufacturer of the spoke tensile strength tester

[@erikev]

amba.de

[@trabink2]

Good job Simon, really..

[@jorgecalderon9678]

Tommy Hilfiger DT Swiss shirts.. bring up that swagger on that staff clothing

[@arsaeterna4285]

5:55 lol I was SO confused about the spokes flying out

[@daveyJ213]

Awesome tour! Thanks.

[@robbchastain3036]

Thanks, Si, that was an amazing tour and everything about that operation is impressive--the people, the spoke stock, worldwide assembly plants, just everything. And cool that the master wheel builder is a downhill world champion and one wonders, just out of curiosity, how his times down the mountain compare with those of the young guns.

[@dtswiss]

Thanks Robb. Highly appreciated

[@1afterthep]

I wish I could buy dt swiss apparel somewhere because I love their logo and colors

[@Pratalax]

Christ, what was in that coffee you were giving him, Si?! That was possibly the most chilled out human on the planet!!

[@lawman1965]

Excellent video. Thanks

[@geoffgovey9093]

Great video. As an Engineer I really enjoy seeing the inside track on how kit is made. Nice one!

[@dtswiss]

Thanks Geoff. Highly appreciated

[@witte2702]

would be curious to see the script for this video. how many times did it say "Simon nods with a look on his face that signifies that he understands", i am about 7 minutes in and at least twice he hasn't managed to pull off the "he understands" bit. ps. really enjoying the factory tour videos.

[@Daluke61]

And you, Mr Black Hand; you sir hereby receive KZbin's Snark Of The Week comment. Its on-point directness as well as well as the troubling imagery it creates in the end truly exemplifies what keeps us all engaged and is an important part of what KZbin's all about... kudos.

[@robear7293]

?

[@baronvonhoughton]

Its know in the trade as a "Noddy". Check out news prog's do it lots, often shot after the interview.

[@bmcriderj]

Oh thanks to the GCN, I could see the procedure of my wheelset fabrication and the factory environment.

[@gcn]

Hope you enjoyed it 👀

[@paucostagraell3449]

1:45 Can that wire make it less than 80 days?

[@gorelalkumar5714]

Pau Costa Graell hi

[@vulgarpestilence]

A Spaghetti 3:27

[@vulgarpestilence]

SirBlot I should have done the same thing...

[@nonamehere9658]

Shpagetti!

[@vulgarpestilence]

noname here Schpagettie

[@pf5840]

Thats how Swiss People say Spaghetti

[@vulgarpestilence]

ptrck flkgr Pretty important!

[@johnobrien5464]

I'm surprised that Si didn't bother to make a big deal about DT Swiss using WD40 in their factory labs 19:34 and try to say that its better than normal bike oil.

[@elidouek5438]

DT Swiss's spoke blackening process is probably nothing more than the Black Oxide process. From my understanding of the process, the spokes are dipped in a alkaline cleaning solution, rinsed in water, dipped in caustic soda (also called Lye, which is what actually blackens the metal by forming a layer of black oxide. It is then dipped in a sealant (usually oil) to 'lock in' the colour. The same process is used to blacken many types of screws, a good example being socket head cap screws. this is also the process that makes guns black.

[@karlwalters3763]

Yep.

[@kelvingrover4043]

I'm look at my rims and thinking about all the process Thank you from Pacific northwest

[@dtswiss]

Thanks Kelving, highly appreciated. Greetings from Switzerland

[@kawasakiman8965]

Amazing the work that goes into making a bike

[@jo-anneyuskin6110]

Very interesting video. Thank you.

[@chauccy]

7:53 torture chamber in German accent sounds extra evil.

[@rajeshnd]

The guy Alex, especially at the end, looks like a younger version of Matt !

[@aacc8466]

Si!!!! That Posture tho!

[@reddaB]

Alan Cardenas Needs to go to a chiro, he'd have some big cracks saved up between his shoulders.

[@noelharrington4786]

Great video really interesting factory

[@luganskukraine]

the dirty rug on the wire looks super high tech! :)

[@yohidai]

I love Alex's walk style.

[@rockroll9473]

I like DT SWISS wheels and hubs.

[@parttroll1]

Ah Si you missed a golden opportunity for a pun. You should have introduced Alex Schmitt as DT Swiss's spokesperson :D

[@strinati]

Awesome vid!

[@earlfoss99]

This video segment is wheely cool.

[@running4fun863]

Simon you have a great job.

[@RideTheAlps]

If you compare it with SRAMs production in Taiwan, you know why you by Swiss and Europe, aside from the transport costs and emissions. And DTswiss has a awesome, leading crash replacement policy for 10 years for MTB wheels.

[@vancel35]

At 1:20 ... I (and my nearly cut off finger) would like to see bladed spokes banned except in a TT. If the UCI is going to keep disc brakes out, bladed spokes are a bit more dangerous. This comment is mainly pointing out the absurdity of the ban on disc brakes; however, I did have a bladed spoke shatter the bone in my left index finger and remove a centimeter of extensor tendon that had to be grafted back together. It happened on May 6th, 2017, and I still don't quite have full use of my finger yet... or even my whole hand since I lost strength overall while it was out of commission.

[@elidouek5438]

when the extent of the injury you suffered, i doubt that the spoke being bladed or not would have made a difference

[@U20101954]

its not about if the spokes are bladed or not, its about momentum, you will have the same outcome even if the spokes are not bladed.

[@vancel35]

It was a crash where we were in a 38 mile road race with a mile of gravel, and several women couldn't control their bikes and got squirrely. I was avoiding each of them when finally one crashed in front of, but off to the side of me by a little more than a car width. Her bike spit out from under her spinning in front of me, then it hit something and pirouetted up tumbling with the wheel at my head level flying sideways. As it came down, it caught my hand on my hood and my fingers. My bike was pulled out from under me to the side. I flew through the air at 26mph into a tuck-and-roll move. When I came up the only damage I had was my fingers, and my first knuckle was up and back from where it should be. It was a complete freak accident, and I don't think anything like that would happen again. I was poking fun at the disc controversy.... stuff happens, and bike racing is dangerous. But I'll keep doing it. :)

[@bobdixon3048]

Laura Vance makes me think about my bladed spokes

[@alexanderdrago9852]

This company its fucking professional .Real pleasure to run great bike in the Swiss Alps .Aaaahhhhh i love it !

[@jjforcebreaker]

I love these videos.

[@hippyhero2424]

They need a presenter with engineering knowledge who can actually converse with these guys while helping to lead the conversation to help explain the processes and possibly highlight some unique features.

[@Gkuljian]

Holy shit. I love Industry Nine, but you can't argue with 1634. That is hard to believe.

[@the23rdshadowdragon]

3.51 why is the sign blurred out? Again at 16.00

[@madbikeboysins]

This is a wheelie good video, and I'm happy to see Si as DT's new spokes-person. See what I did there?

[@steventrott8714]

God I love a good pun, but you should have just left it open. Do you know what I mean?

[@DrBreezeAir]

You are punishing me guys.

[@pieterbrankaer]

Also the talk about wheel world testing 😁

[@DrBreezeAir]

I’m gonna order me DT Swiss wheels for the next season. My dear Crux will love them.

[@dtswiss]

thx

[@basantkumar2092]

@@dtswiss jjj

[@basantkumar2092]

Jjj

[@basantkumar2092]

Jjjj

[@basantkumar2092]

Jj

[@Pozi_Drive]

I wonder what the hammer is for at 14:25 on the red machine.

[@chrisdaigle5410]

Founded 1634 to make wire for chain mail armor. Wow.

[@ef5936]

Best wheels ever!!!

[@dtswiss]

Thanks, highly appreciated

[@AlexRochette]

@ 20:15, What bike is Alex (DT Swiss dude) riding?

[@osmanidris8494]

Mavic 217 rim, Chris King hubs and DT Swiss Spokes are still perfectly serving after 20 years of abuse. :D

[@EkoKolo_Katowice]

Greetings from Poland :)

[@4strokealberg]

is the matt black bike, Alex rides a Focus Cayo???

[@pedicaboyou6778]

Where do you find a factory with workers all in bike shorts? DT Swiss of course!!

[@britishnumismatists3910]

Hey GCN, I recommend you doing a video on the carbon fiber KTM bikes, they seem to be neglected lol

[@mitchellsteindler]

Cartier Pham they make road race bikes

[@Charles-wz9sd]

They are very hard to obtain and ktm needs to reach out the GCN. Dt Swiss, poc and all those other brands reached out to them for the videos

[@newwarez1]

0:36 I thought he is meeting with himself.

[@garlic.naan2]

When will the video you filmed at the Wessex league cyclocross be posted?

[@studio_Pikunov]

очень нравятся ваши видео!

[@LUCYDIAMONDBOXER1]

4:26 we have a secret area where we stretch and hammer our spoke....🤔 Employee perks?

[@PopkosCZ]

Got DT Swiss wheels (PR1600) and got that tingling noise for about 3500 km until the wheel probably settled itself..

[@Dr4g0nW00d]

Bought myself the Dt swiss XM 1501 spline one centerlock wheelset

[@_broody2853]

Cudo's on the vid! ... Cudo's to GCN for a great subject! ... Cudo's to DT Swiss for making awesome stuff!

[@dtswiss]

Thx. Highly appreciated. Greetings from Switzerland

[@kathr2773]

wow so much HepcoMotion MCS aluminium profile in that torture chamber, it's heavenly!

[@ZiggZagg11]

I want to see how the Chinese mass build wheels for the masses... Do they still hand tension them or somehow have a machine that tightens all the spokes at once...? Do they have people hand weaving the spokes into wheels...? Think about the massive quantities to supply all the bicyles...

[@matthewbradshaw8017]

ZiggZagg11 unless you are buying high emd wheels, they will pretty much always be machine laced and tensioned

[@Charles-wz9sd]

If you get something around $2000 and up, the company will hand lace them. Most of the wheels that are hand laced are done with the help of a computer rather than a master wheel doing it by their experience.

[@mayalman]

ZiggZagg11 I suspect Yoeleo hand tensions their spokes as a wheel order takes 30 to 50 days to complete

[@CGPhotos]

@mayalman I agree, a superb wheelset for less than 600

[@fiddleronthebike]

they are made exact in the same way and with the same tools as shown here in the video - only at another location and from other people...

[@brucetumblinjr7980]

I just purchased a set of DT SWISS hoops

[@cwb66]

3:26 I find this so amusing for some reason

[@ChillOutDood]

My LBS told me that dt swiss spokes are being made in China now, at least a portion of the new batches. He had to go with some sapim double butted for my build.

[@andrewrae3123]

The bounce weight test in the video was done at 40 jules, +-4kg and the flat surface area hitting the spinning wheel is way broader than the wheel. A child bunny-hopping a bmx on flat road, maybe. How about using a rod or or dowel contact point and applying 90+kg or rider weight. I.e. Avg rider hitting pot-hole at speed

[@45graham45]

Where / who manufactures the rims for DT Swiss?

[@catha86]

Yeah this is why the quality is so high.

[@davidmarshall2399]

a bunch of enthusiastic party people at DT Swisse

[@aidanf2610]

Like a shpegetti 3:27

[@Alejandro-vb2fx]

20:33, ole Alex there Is packing more than knowledge about DT Swiss products hahaha. Dude looks like me in tights.

[@Pozi_Drive]

www.procyclingstats.com/rider/alex-schmitt

[@Ri4Fu]

I work acros the street from there :D

[@izi941]

What's the intro song? GTN also uses it..

[@andyzacek9760]

Most of DT Swiss product line, basically 100% of their alloy rims and all their forged/casted products are made by Giant in Taiwan

[@sergio895]

I will die due to that sound. Holy shit.