a custom wheel set designed for the Chevrolet Corvette C5 (1997-2004) that brings Corvette’s history and lightweight ethos to the road
private commission for an exclusive member of the Audrain Auto Museum, Newport, RI.
COSMOS WHEELS
5 x 120.65
18 x 9.5 J ET+53
19 x 11 J ET+54
Forged 6061-T6 Aluminum
Silver Metallic with Polished lip
Jan 2025 / 4 Months
Product Design, Production, Engineering, Motion
SolidWorks, AutoCAD, Visualization
Bolt Pattern
Front Size
Rear Size
Material
Finish
Duration
Type
01
Understanding Demand and Setting Criteria 
classy
More than 85% of the current aftermarket wheel options for the Corvette C5 are described by the client as “too extreme”. Often having chrome and huge wheel lips, these wheels need additional body modifications to look good on the car.
BOLD
The Corvette C5’s factory wheel design is uneventful: thin, five-spoke, polished, and that’s about it. It does not stand out but is often neglected. The client wants a bold design that grabs attention immediately while flowing along the curvy lines of the bodywork.
TASK
Design a wheel set for the Chevrolet Corvette C5 that is different from any other options available.
Communicate with the client to help find out the demand.
Follow the design criteria to deliver the requirement and meet the manufacturing and safety standards.
Source a licensed manufacturer who is willing to take one-off/small batch orders.
02
Design Approach
Moodboard
Simplicity and curvature become the two most important elements that shapes the wheel.
To follow the “classy” design criteria and guide the client to a desired design direction, a moodboard is created, consisting of period-correct images and automotive designs.
After rounds of discussions and decision-making, the initial design of the Cosmos wheel is set to be derived from two cars: the 1997 Alfa Romeo GTV 3.0 V6 and the 1988 Lamborghini Countach 5000 QV. Sharing the same five-hole phone dial look, the wheels on both cars lie along with the criteria and ethos of the project. The five circular holes give enough opening to air flow, which helps the brakes to cool and assert visual hierarchy, while the rest of the wheel face leaves enough space for CMF to shine and not take too much attention away from the car’s body. The balanced geometric shape fits perfectly with the “bold” and “classy” theme.
SKETCHES
Renderings
Production-ready design done in KeyShot
03
ProductionTo ensure production measurements, a technical drawing is created in SolidWorks as a rough reference. A specialty manufacturing company based in Northeastern China is contacted for their appropriate forging machinery and competitive pricing.
Part of the Chat history with the manufacturer.
CAD model transported from SW into AutoCAD for better accuracy and compatibility with the aluminum blanks that will be turned into the Cosmos wheel.
Iteration 1. wrong concave shape
Iteration 2. concave not deep enough
Iteration 3. finalized design with export-only aluminum blank
Logo Design
A special logo is designed for the Cosmos wheel. Differing from the original Corvette C5 logo (middle), the central “C” design stands for the initial character of both “Corvette” and “Cosmos”. Rooted in the precise aesthetic of construction-grid style (right) and geometric minimalism, this logo exposes its foundational geometry to highlight structural logic and exact proportion of the Cosmos wheel.
04
Shipping
Shipping arranged through international shipping representative. Final product tested with maximum load weight of 900 kg front and 1200 kg rear to handle road conditions in New England.
05
Product2025 Audrian newport concours & motor week co-event
Photo Credit: Ray Liu (RISD ID 26)
