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Active Aero Wheel

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~10 % savings
~5 % savings
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Active Aero Wheel – Aerodynamics Meets Intelligent Brake Cooling

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The automotive industry faces a key challenge: reducing air drag to improve energy efficiency while ensuring that the braking system remains sufficiently cooled. Lowering drag enhances vehicle range and fuel efficiency, but an open wheel design is often necessary for effective brake cooling.

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With Active Aero Wheel from CompActive, we solve this contradiction. Our innovative wheel significantly reduces air resistance while ensuring optimal brake cooling—only when needed. Thanks to an intelligent, purely material-based solution that operates without electronics or moving parts, we offer a particularly robust and low-maintenance technology for modern vehicles.

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Maximum Efficiency Through Reduced Air Turbulence

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Aerodynamics play a crucial role in vehicle efficiency. The Active Aero Wheel is an advanced innovation that dynamically shifts between an open and a closed wheel design, depending on driving conditions.

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Conventional wheels are either:

  • Always open, providing continuous brake cooling but increasing air resistance, or

  • Permanently closed, improving aerodynamics but risking brake overheating.

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Our system combines the best of both worlds:

✔ Closed when possible, reducing air resistance by up to 10% for improved range and efficiency.
✔ Opens when necessary, ensuring optimal brake cooling only when required.

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This adaptive technology results in lower energy consumption, maximizing battery efficiency. A 5% reduction in air drag compared to partly closed rims can lead to a smaller battery pack without sacrificing range, cutting costs, weight, and space requirements.

A Robust Solution for Extreme Conditions

The Active Aero Wheel is based on an innovative, heat-activated technology that functions without mechanics or electronics. This makes our system extremely reliable and resistant to environmental influences.

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Technical Features:
✔ A one-part solution without electronics – maintenance-free and durable.
✔ Resistant to extreme conditions – withstands water, salt, dirt, ice, and high acceleration forces.
✔ High-quality materials – stainless steel 1.4310 for maximum strength.
✔ Metal fixation and protective covers – ensuring a robust and secure design.
✔ Flexible mounting options – allowing easy integration into various wheel designs.

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This carefully engineered solution makes the system exceptionally long-lasting and suitable for even the toughest conditions.

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Customizable Aesthetics

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Beyond its functional benefits, the Active Aero Wheel offers extensive customization options. High-quality heat-resistant coatings and custom engravings allow the OEM to tailor the design so that it seamlessly integrates into the overall concept of the target vehicle.

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Available Finishes & Customization Options:

  • Diamond-Like Carbon (DLC) – a highly durable, scratch-resistant coating.

  • Ceramic Coating – for an elegant appearance and high-temperature resistance.

  • BLack Oxide Coating – for a bold and premium finish.

  • Localized Matting via Laser Engraving or Etching – creating unique patterns and textures.

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With these flexible design choices, the Active Aero Wheel seamlessly integrates into any vehicle’s aesthetic concept.

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From Concept to Series Production – Your Path to a Customized Aero Wheel

We offer a streamlined process to help you implement the Active Aero Wheel into your vehicle design.

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Your Customized Solution in Four Easy Steps:

  1. Select your wheel orientation and base design.

  2. Define the opening geometry to optimize airflow.

  3. Customize the look with premium coatings and engraved patterns.

  4. Receive your tailored solution - from prototype to mass production.

 

Production & Delivery Times:

  • Proof of Concept (5 - 50 pieces): Delivered in under 4 weeks.

  • Pre-Series Testing (200 - 800 pieces): Delivered in under 10 weeks.

  • Series Production (>10,000 pieces): Start of production within ~12 months.

Thanks to our scalable manufacturing processes, we can meet all requirements—from small batches for concept vehicles to full-scale production.

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Flexible Integration into different Rim Systems

Our system is designed for seamless integration into various vehicle configurations.

  • Direct Rim Integration – Minimal component count, all-metal design for maximum durability.

  • Integration via Inserts or Hubcaps – Allowing for additional design flexibility using customized plastic elements.

 

In collaboration with our industry partners, such as Borbet and mbDESIGN, we offer tailor-made solutions for complete rim systems at every stage — from the design study to series production — perfect for OEMs seeking an innovative, aerodynamic, and visually appealing solution.

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