A batch of freshly made DT Swiss spokes leaves the threading machine and will soon be on its way to join a wheel. (DT Swiss photo)
DT Swiss uses a type of radial forging machine to butt its spokes that operates similar to this drawing. Also called rotary swaging machines, they operate by rotating a ring of rollers (7) that press down on plungers (2) as they roll over them (9). The plungers squeeze dies (3) that force the spoke (5) into a smaller diameter as it is fed through. Radial forging is a very precise and repeatable method of forming round shapes. (US Patent drawing) screw
DT Swiss uses a different forging process to profile its bladed spokes. Top secret, of course. (RC photo)
DT Swiss states that the type of application, not superior strength, is the determining factor for using aluminum nipples rather than conventional brass items. They offer square, hexagonal and Torx type drive interfaces as well as a variety of anodized colors. (DT Swiss photo)
A split view of a DT Swiss Pro Lock nipple shows its pre-applied thread-locking material, as well as the unthreaded section of the bore that acts as a stress reliever where the spoke enters the nipple. (DT Swiss photo)
Spiral grooves in a pair of rotating bars advance blank spokes through this machine, where they are measured, cut to precise length and the threads are rolled onto the ends. (DT Swiss photo)
The classic 'J' bend spoke head of the DT Swiss competition spoke. Reportedly, the J-bend will stand up to an equal amount of abuse as a straight-pull spoke will - as long as the hub flange design is correct. (DT Swiss photo)
Tricon hubs use double-threaded, straight-pull spokes, partially because DT Swiss must weave the spokes into an undrilled tubeless rim during the build process. (RC photo)
DT Swiss uses a special 'anodizing' process to produce its black spokes. White and spokes featured in other colors are actually painted individually. (DT Swiss photo)
Second Punch The DT Swiss factory in Biel, Switzerland. Spokes in one millimeter increments are packed by the hundreds in cardboard boxes on the left, destined for bike shops and specialty wheelbuilders - and by the thousands in the metal boxes on the right, earmarked for OEM manufacturers around the world. (DT Swiss photo)