The New Hot Shit? What everyone should know about the new wheel size!

32-inch is in the starting blocks and is pushing hard into the market. Behind the scenes of the bike industry, work is underway everywhere to adapt and, ideally, test new concepts. However, alongside the well-known advantages of larger wheels (better rollover characteristics, more stability, and increased speed), the jump to 32“ also brings many challenges - and not just for wheel manufacturers.
32-inch wheels are not only 64 millimeters larger in diameter than the familiar 29ers; they also possess other unique characteristics you should be aware of. To put this upcoming wheel evolution to the test - or rather, to the spokes - we at NEWMEN built over 60 different wheels and tested them in the lab. To bridge the gap between theory and practice, we simultaneously took around 20 wheel configurations out for field testing on the trails.

And why all this effort?
Because as component and wheel specialists, we feel a responsibility to provide our entire body of knowledge and expertise to all our customers, from bike manufacturers to end consumers. Only in this way can we benefit from the lengthy development steps of the past and bring the best possible 32-inch bikes to market from the very beginning. It is better to meet the requirements of these significantly larger wheels right from the start, rather than enduring a costly „cold start“ at the expense of the end consumer.

Let’s do it better this time!

What is currently happening with the new 32-inch supersize wheels is exactly what we went through nearly 20 years ago during the transition from 26 to 29 inches. Out of initial experimentation, combined with a few missteps, unified standards only developed over several years. There is a good reason why today’s 29er MTBs all roll across the trails with wider flange spacing. Boost hubs - and in some cases, even Super Boost hubs - were the means to an end to compensate for the reduced wheel stiffness compared to 26-inch wheels.

Now, the same problem is knocking on the door with the jump from 29 to 32 inches. Quite literally, as a look at the standardized ETRTO measurements reveals. While the jump from 26 to 29 inches was 63 millimeters, this time it is 64 millimeters from 29 to 32 inches. However, „bigger“ doesn’t just mean more speed; unfortunately, it also means more weight and, on top of that, less stiffness. These „big wheels“ flex a significant 31 percent more under the same lateral load.

But aren’t current 29-inch wheels already too stiff anyway? Why else would enduro and downhill racers be using every trick in the book to remove stiffness from wheels to improve handling characteristics? That may be true for some. However, not every athlete weighs under 80 or even 70 kg and has a dedicated team of mechanics happy to lace up a handful of new wheels over a race weekend. E-MTBs with permissible total system weights of up to 150 kg are a common reality and stress wheels more than you might think. 32-inch wheels should be prepared for this scenario as well, rather than focusing only on lightweight riders with gravel and cross-country aspirations.

But how stiff is optimal, and when does a wheel become too soft? Our extensive field tests have shown that lateral stiffness should not fall below a certain value to maintain a precise, controllable ride feel. On the test bench, this limit can be defined as 8.5 mm of deflection under a lateral load of 300 Newtons.

It’s not just about ride feel; long-term durability also plays a crucial role in wheel stiffness. If stiffness is too low, spokes can more frequently and easily become completely unloaded during riding. This immensely increases maintenance requirements due to loosening nipples and the resulting drop in spoke tension. Here, wheels with slightly higher stiffness - resulting in less than 8.5 millimeters of deflection - score significantly better and reduce the need for servicing.

Simply making the wheel larger and „seeing what happens“ cannot be the solution. To avoid compromising both precise handling and long-term durability, 32-inch wheels must be built differently. Spoke count, spoke type, and - last but not least - the hub spacing (and thus the flange distance) must be carefully selected and optimized where necessary. This applies to both Gravel and MTB use.

Our extensive laboratory and field tests regarding wheel stiffness have yielded the following results:

Evaluation of Lateral Wheel Stiffness: 28/29“ vs. 32“ (ETRTO 622 vs. 686 mm)

1. Wheel Diameter
28/29 vs. 32 Zoll

2. Spoke Type
Sapim Laser (2.0-1.5-2.0) vs. Sapim D-Light (2.0-1.65-2.0)

3. Hub Width/Flange Spacing
Gravel
FW: 12x100 Non Boost vs. 15x110 Boost = Flange spacing 53 mm vs. 63 mm
RW: 12x142 Non Boost vs. 12x148 Boost = Flange spacing 54 mm vs. 60 mm
MTB
FW: 12x100 Non Boost vs. 15x110 Boost = Flange spacing 53 mm vs. 63 mm
RW: 12x148 Boost vs. 12x157 Superboost = Flange spacing 60 mm vs. 69 mm

4. Spoke Count
28 vs. 32 holes

1. Wheel Diameter (29 und 32 Zoll)

With an identical build, a 32-inch wheel is, on average, 31.36% softer than a 29-inch wheel under lateral load. Depending on the spoke type, this difference varies marginally: 33.7% with Laser spokes and 29.01% with D-Light spokes.

2. Spoke Type (Sapim Laser vs. D-Light)

The heavier D-Light spoke (+41 grams for 56 spokes in a 32-inch wheel) increases lateral stiffness by 7.54% given an identical build.

3. Hub Width / Flange Spacing

Gravel Front Wheel
12x100 Non-Boost vs. 15x110 Boost = Flange spacing: 53 mm vs. 63 mm

On the front wheel, increasing the flange spacing by 10 millimeters results in a 15.5% improvement for the 32-inch wheel.

Gravel Rear Wheel
12x142 Non Boost vs. 12x148 Boost = Flange spacing: 54 mm vs. 60 mm

Increasing the hub width - and the resulting wider flange spacing - improves wheel stiffness with a manageable weight penalty of only ten grams per hub. On the rear wheel, broadening the hub width from 12x142 (Non-Boost) to 12x148 (Boost) increases the stiffness of a 32- inch wheel by 11.5%.

MTB Front Wheel
Currently, there is no hub standard wider than 110 millimeters for the MTB sector. A „Super Boost“ front wheel (e.g., 15x120) would be the next logical step. With a deflection of 7.55 mm, 32-inch front wheels are just barely stiff enough even with lightweight Laser spokes; however, they could be further optimized with a wider hub standard and flange spacing to be stiffer, or to use fewer/lighter spokes.
A 15x120 Super Boost front hub would achieve the same stiffness as a 29-inch wheel using the same spoke count and without requiring heavier spokes.

MTB Rear Wheel
12x148 Boost vs. 12x157 Superboost = Flange spacing: 60 mm vs. 69 mm

On a mountain bike, the +9 mm jump from the common 12x148 (Boost) standard to 12x157 (Super Boost) yields a 16.4% increase in stiffness for a 32-inch wheel, assuming identical spoke types and counts.
By optimizing the flange width with the 12x157 Super Boost standard, it is possible to achieve identical stiffness to a 29-inch wheel - with the same spoke count and without heavier spokes.

4. Spoke Count (28 vs. 32 holes)

Increasing the number of spokes used can also improve the stiffness of the wheel. Using 32 instead of 28 spokes per rim improves the lateral stiffness of a 32-inch rear wheel by 10.87 percent. However, the four additional spokes add an extra weight of 49 grams (D-Light) per wheelset.

Conclusion

  • 32-inch wheels are 31 percent softer than 29-inch wheels under lateral load when using an identical build.
  • To increase the stiffness of 32-inch wheels, heavier spokes can be used. A weight increase of 41 grams (28 holes, 32-inch) per wheelset yields 7.5 percent more stiffness.
  • Increasing the spoke count from 28 to 32 also results in 10.9 percent higher stiffness for 32-inch wheels, with an additional weight of 49 grams per wheelset.
  • With only a minimal weight increase at the hub (approx. +10 grams each), the hub width and thus the flange spacing can be increased to improve lateral stiffness. Expanding the flange spacing by the maximum possible nine millimeters (from Boost to Super Boost) on the rear wheel can increase the lateral stiffness of a 32-inch wheel by 16.4%. A 32-inch Super Boost rear wheel is thus nearly as stiff as a 29er rear wheel with Boost spacing. On gravel bikes, widening the rear hub from 142 to 148 millimeters provides 11.5 percent more stiffness.
  • On a 32-inch gravel front wheel, increasing the flange spacing by ten millimeters results in a 15.5 percent improvement.

Key Takeaways from the Diagram

  • Increasing hub width delivers significantly more stiffness per gram.
  • A higher spoke count can increase stiffness slightly more than using thicker spokes, though the weight gain is also slightly higher.

Important Facts for Manufacturers

  • Increasing the hub width does not incur any additional costs.
  • Increasing the spoke count raises the costs for spokes and nipples.
  • More spokes also mean more truing time and, consequently, higher wheel-building costs.

General Aspects of 32-Inch Wheels

Since the new 32-inch movement doesn‘t stop at the wheel itself, other involved components also deserve a closer look.

Brakes
Due to the increased wheel diameter, the spokes have a different spoke angle. They run more vertically (straighter) and thus move closer to the brake caliper, which can lead to clearance issues and collisions. Shifting the brake-side spoke flange toward the center of the hub to create space would, in turn, cause an even greater decrease in stiffness.

Additionally, the larger wheel diameter changes the leverage ratio between the wheel and the brake rotor. Braking power is reduced by almost exactly 10 percent on a 32-inch wheel compared to a 29-inch wheel. To achieve the same braking power, one would need to mount a 220 mm rotor instead of a 200 mm rotor, or a 180 mm rotor instead of a 160 mm rotor. This adjustment would, conveniently, also help offset the clearance problem caused by the straighter spokes.

Fork and Frame
To integrate the larger wheels into the fork and rear triangle, both the axle-to-crown length and chainstay length must increase. These longer levers, in turn, put greater stress on the frame - particularly the entire head tube area. Since head tubes on 32-inch bikes are already designed to be very short to maintain a low front end, the resulting load on both the fork and the frame is further intensified.

Stem and Steerer Tube
The guiding principle here is to keep things as low as possible to compensate for the increased axle-to-crown length. However, the low clamping height of the stem increases the stress on the steerer tube. Increasing the diameter or the wall thickness would therefore be worth considering and potentially useful. Since negative-rise stems will need to be specified for 32-inch bikes - especially for smaller frame sizes - the variety of available stems will increase. Consequently, stems will vary significantly more in their angles, in addition to their lengths.

What Bike Manufacturers Must Know

  • Lightweight yet sufficiently stiff 32-inch wheels are not possible using conventional, narrow Boost spacing.
  • Increasing the spoke count from 28 to 32 steel spokes results in additional costs of €1.50 to €3.00 per wheel (including the extra labor for lacing, nippling, and truing). For a production volume of 100,000 bikes per year, this totals an additional €300,000 to €600,000 and adds 5,600 kg of unnecessarily installed spoke material.
  • Should a move to 36 spokes be planned for stiffness reasons, the figures mentioned above would double.
  • For wheels with carbon spokes, an increase in the spoke count has an even more significant impact on the price. An increase from 24 to 28 spokes would add €10 to €20 per wheel (spokes including wheel building).
  • More spokes negatively affect the aesthetics and generally tend to look cheap.
  • A higher spoke count is proven to worsen aerodynamics.

Our Recommendation for 32-Inch Wheels

Gravel
For gravel bikes, the transition from Non-Boost to Boost at both the front and rear is recommended, as this involves no additional costs. By utilizing Boost, it remains possible to build lightweight 32-inch wheels with a low spoke count and light spokes. This standard also allows for the construction of sufficiently stable wheels - for instance, for bikepacking or heavier riders - without the need for unnecessarily heavy or excessively numerous spokes. Furthermore, the brake rotor mounts on the fork and frame should each be increased by one size, such as from 160 mm to 180 mm or from 180 mm to 200 mm.

MTB
On mountain bikes, a switch from Boost to Superboost at the rear is essential and incurs no extra costs. Due to the longer chainstays required for these wheels, the Q-factor does not even need to be increased. The same advantages as in the gravel sector apply here: Superboost allows for the continued production of lightweight 32-inch wheels with low spoke counts and light spokes. It also provides the opportunity to build stable wheels for more extreme use cases or heavier riders without resorting to unnecessarily heavy spokes or spoke counts. If the hub width were increased in the same proportion as the wheel diameter jump from 29 to 32 inches, a completely new rear spacing of 163 millimeters with a 75 mm flange distance would actually be necessary.
At the front, a slightly wider mounting dimension would also be desirable; a 10 mm jump from 15x110 to 15x120 would be sufficient and easily implementable. Additionally, the brake rotor mounts on MTB forks and frames should be increased by one size, moving from 180 mm to 200 mm or from 200 mm to 220 mm.

It is important to emphasize that with 32”, there is the possibility to start with a clean slate regarding hub width. There is no objective disadvantage whatsoever to increasing the hub spacing for all 32” wheels.