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New DT Swiss RevoLite Spokes Strike Fluted Balance of Lightweight, Extra-Strength & Aero

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes
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DT Swiss has an all-new light & strong premium steel spoke with a cold-forged, fluted profile called the RevoLite. Something of a mash-up between their best lightweight round double-butted spokes and their best lightweight aero-bladed spokes – this one ends up with a round center flanked by squared-off wings throughout the reduced mid-section in the spokes’ overall length.

So what do you get when you mix Revolutions and AeroLites? The result is a spoke that combines lightweight, increased stiffness, and improved durability – an ideal balance for building light & strong off-road wheels.

DT Swiss RevoLite lightweight & strong, semi-bladed steel spokes

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, details
all photos c. DT Swiss

Can I just nerd out for a few minutes on why DT Swiss created these truly all-new RevoLite spokes? I mean, who among us thought that we really needed a completely new cold-forged steel spoke shape that was somewhere between aero and not, in an effort to increase strength and keep weight down at the same time?

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, silver or black

I build all types of wheels for my own use – for road, cyclocross, gravel, touring, XC, trail & enduro – and I was perfectly happy with either picking DT AeroLite spokes when I wanted to build something more aero or really stiff, or picking a DT Revolution spoke when I wanted a lightweight wheel with a bit more give for riding harder off-road, and with fewer sharp edges. Sure, I’d sometimes build a wheel with Sapim spokes, but I never felt like DT’s offerings didn’t do everything I needed for a stainless steel spoked wheel build.

Plus, if I wanted something ultralight, I’d likely task a more experienced builder to try something silly like flexible fiber or bladed carbon spokes.

OK, spoke nerd rant over.

What’s Actually New?

spoke manufacturing in Switzerland from our Factory Tour

The RevoLite is made by DT Swiss in a new, and tightly-guarded process similar to their top bladed spokes. As we saw when we toured DT Swiss’ HQ in Switzerland a few years ago, coils of stainless steel wire get straightened and cut into spoke lengths. Then, premium double-butted spokes go through a cold-forging process where automated rotating and oscillating hammers smash the straight spoke blanks to make them skinnier and give them butts – making the spoke a smaller diameter in the middle than the ends, effectively increasing elasticity. This process aligns the structure of the metal and increases its density (also a bit longer).

Premium DT AeroLite spokes then go through a 2nd flat cold-forging step that hammers them another time to give their central butted section the aerodynamic blade, also making it stiffer and increasing tensile strength.

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, cross section

Now like those AeroLites, the new RevoLites also combine these multiple round & flat forging techniques (although DT is vague on their precise patented process). This time though, it seems a specially shaped mandrel must be used to create the new spoke’s unique pseudo-cross-shaped cross-section. The resulting fluted shape in section appears to have a thing circular middle, crossed with a box-shaped wing.

DT says this creates a spoke that is extra stiff like an aero wing spoke, lighter overall due to the thinner section from the cold-forged butting, and still as durable against repetitive stress like a round-butted spoke because of the constant circular section through the thinnest part of the spoke.

Where does it sit in the DT spoke lineup?

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, 2x in MTB wheel

DT calls the new RevoLite the best mix of durability and lightweight in their MTB spokes. That’s an important delineation, as the on-road-focused AeroLite is lighter and equally as stiff, and it is also not the absolute lightest in the MTB line-up.

Weight-wise, DT claims the stiffer bladed RevoLite to be 4.45g per spoke (260mm), compared to the simply double-butted Revolution at 4.42g (264mm) or the thicker but still butted Competition Race at 4.88g (260). Compared to the aero-bladed road spokes, the butted AeroLite is lighter at 4.34g (264), while the thicker but still butted AeroComp is 5.9g (264).

Price-wise among DT Swiss standard silver steel spoke offerings, per 20-pack of spokes the new RevoLite is effectively the same price as the top aero spoke at ~50€ for the AeroLite. The AeroComp costs ~30€, Revolution ~22€, and Competition Race cost around 18€ for the same set of 20.

Unsurprisingly with it more complex cold-forged shaping, the RevoLite is clearly the top-tier of spokes for off-road wheels, while only giving up about a 2.5g weight penalty over their absolute lightest spoke in a complete modern wheelbuild.

Tech details

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, Tech Details

The DT Swiss RevoLite is a double-butted, bladed (fluted?) stainless steel spoke – 2mm in diameter at either ends, and first butted to approximately 1.57mm in the middle before the bladed shaping. The resulting bladed/fluted cross section in the middle is 1.3mm across in the smaller dimension (the circular central shape) and 2.3mm across in the wider dimension so it will still fit through regular round spoke holes in your hubs.

All spokes get a DT stamp on their head. J-bend spokes feature a 90-95° head with a low 6.2mm head height (from outside of the head to outside of the spoke) to ensure a smooth, tight fit against modern thin hub flanges. Threads are rolled on the 2mm spokes to FG 2.3mm.

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, laced to DT 240 hub

Even with the unique new bladed shape, DT assures us that the new RevoLite spokes can be built up and tensioned with a standard aero spoke holder. And wheel builders can use their regular spoke tension meters. DT has updated the ideal tension numbers in the charts for their Tensiometer for the new spoke.

DT Swiss RevoLite – Pricing, availability & options

DT Swiss RevoLite all-new premium lightweight bladed double-butted stainless steel mountain bike spokes, black cross-shaped spoke

The DT RevoLite spokes are available in 194-316mm lengths with a traditional J-bend or a straight pull head, in classic silver or more stealth black. Officially they sell starting at $70 / 50€ for packs of 20, or $350 / 251€ in packs of 100. Get them now wherever you buy DT Swiss wheelbuilding components, or have a reputable wheel builder laced them into your next mountain bike wheelset. I’ll for sure build some new off-road wheels this summer with the new RevoLites.

DTSwiss.com

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Fake Namerton
Fake Namerton
8 months ago

These look great but no idea why I’m reading this article knowing full and well I’m still going to cheap out and get lasers when I build a set of wheels.

Dominic
Dominic
8 months ago
Reply to  Fake Namerton

Hard to go wrong with lasers really.

thesteve4761
thesteve4761
8 months ago
Reply to  Dominic

Windup. Windup is where you go wrong with a Laser.

Slappy
Slappy
8 months ago

bet they’ll be fun to clean

Fake Namerton
Fake Namerton
8 months ago
Reply to  Slappy

How would they be that much harder to clean in comparison to CX-rays etc. cleaning spokes is like 1 second wipe with a soapy sponge.

Roger Pedacter
Roger Pedacter
8 months ago

DT makes great stuff but this seems more marketing driven than performance driven.

Look, we changed the rolling die to a fluted shape and (to paraphrase) this one goes to eleven.

Veganpotter
Veganpotter
8 months ago
Reply to  Roger Pedacter

It definitely makes sense that these are stronger.

satanas
satanas
8 months ago
Reply to  Veganpotter

Because DT’s marketing says so?!?

Fake Namerton
Fake Namerton
8 months ago
Reply to  Roger Pedacter

This explained like 99% of bicycling products.

Chris White
8 months ago

I’m not interested in these, but adding a load more SKUs for suppliers to stock will make it even less likely that the model I actually need is currently available, so I’d be happier if it didn’t exist.

Onawalk
Onawalk
8 months ago
Reply to  Chris White

Cool story bro, really feeling for ya over here. Must be tough for you to not get what you want, exactly when you want it. Is there some sort of gofundme set up for your issues that others can donate too?

Roger Pedacter
Roger Pedacter
8 months ago
Reply to  Onawalk

You seem like you’re probably lots of fun at parties.

Onawalk
Onawalk
8 months ago
Reply to  Roger Pedacter

I am for sure, I’m pretty sarcastic, like to joke around, have fun, and usually bring some interesting beers. What I don’t do is cry in my beer when someone else doesn’t like it, I listen to their criticisms (try to pull out the nugget of truth) and move on. Sometimes they’re right (that beer really is too hoppy to taste the mandarin) sometimes they just want to beer snob me (what the hell is an IBU, or mouth feel anyway)
it’s cool not to be interested in something, but to be happier that it didn’t exist, sheesh, variety is the spice of life they say.

be cool out there bruh, and better get yourself a helmet if my comment bothered you so much, life’s gonna be tough

Jonas
Jonas
8 months ago

Someone at DT saw Colnago marketing material from 40 years ago and thought to apply the same principles to their spokes. Finally a matching spoke for my Master Piu.
In all seriousness though, I see no reason to choose this over an aerolite.

Technician
Technician
8 months ago

350 USD for a 100-pack of a simple steel wire… FFS, DT Swiss staff must be running low on their Rolls Royce collections in the garage.

thesteve4761
thesteve4761
8 months ago
Reply to  Technician

I think this is pretty obviously no longer just simple steel wire.

TrentV
TrentV
8 months ago
Reply to  Technician

And thus why companies like Pillar and CNspoke are doing well.

Larry Falk
Larry Falk
8 months ago

Is this spoke less aero than the double-butted spoke? Looks like it creates a lot of turbulence.

thesteve4761
thesteve4761
8 months ago

Quantifiy the durability increase with actual numbers. Otherwise, this is BS.

Nothing above justifies a 3x price increase in spokes (vs. Competition Race or Supercomp).

Supercomp is (was?) their best mtb spoke. And is MUCH cheaper. Fits hubs well, maximizes alloy nipple strength, and has a nice long narrow section for isolating load.

Fake Namerton, II
Fake Namerton, II
8 months ago

Does Park Tool ever update their tension chart for specialty shaped spokes like these and the Pillar Wing? That would be nice for all of home wheelbuilders and wheel maintenance practitioners.

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