Cold forging compresses the spoke wire under oscillating hammers to densify the material and reduce the center section to 1.5mm. The Aerolite from DT Swiss then undergoes flat forging under high pressure to create the bladed profile while further strengthening the steel. This two-stage manufacturing process produces the lightest flat spoke in the DT Swiss range without sacrificing structural integrity. The cold forging actually work-hardens the metal rather than weakening it through stretching like conventional butting methods.

The spoke measures 2.0mm at the thread ends, tapers to 1.5mm through the butted center section, then flattens to a 0.9mm x 2.3mm blade. That blade width stays narrow enough to fit standard spoke holes without requiring hub slotting or modification to your hub flanges. Swedish X5 stainless steel handles spoke tension while the bladed shape cuts through air more efficiently than round profiles. The flat section runs through the middle portion where aerodynamic gains matter most while maintaining round geometry at the critical stress points.

Available in J-bend and straight-pull configurations across a length range from 194mm to 310mm. The spoke threads use a rolled process that preserves the grain structure of the steel rather than cutting material away, which concentrates stress at the threads and leads to premature failure. Lengths are measured from the inside of the bend to the thread tip for J-bend versions, or end-to-end for straight-pull configurations. Compatible with DT Swiss brass or aluminum nipples sold separately.... Read More