3D Printed Airless Tyres Combine Elastomers With Impact-Absorbing Geometry
Print&Live, working with iSCALE3D, has developed fully 3D printed airless tyres for unmanned ground vehicles (UGVs). The design replaces the pressurised chamber of a conventional pneumatic tyre with an internal lattice structure. Intended applications include evacuation and logistics robotics, agriculture and defence.
The project combines elastomers and composite polymers with a geometry designed to absorb impacts. According to the developer, the tyres have undergone field use, with pilot production listed for 2026.
Replacing Air Pressure With Structure
Pneumatic tyres rely on compressed air to support loads and cushion movement. However, sharp rocks, wire and other debris can puncture the tyre and immobilise a vehicle. An airless design removes this particular failure mechanism because it has no pressurised chamber.
In the Print&Live and iSCALE3D design, an elastic internal lattice provides cushioning through its structure. The developer states that this geometry absorbs impacts and retains its shape even after damage. Removing the air chamber prevents pressure-related punctures, although it does not make the wheel immune to material or structural damage.
Printing Tread and Structure Together
The tyres are printed layer by layer from elastomers and composite polymers, integrating the tread and supporting structure into a single piece. This approach places material properties and internal geometry at the centre of the design: together, they determine how the tyre deforms and supports the vehicle.
The wheel assembly also incorporates a two-part rim made from carbon-fibre-reinforced nylon. The rim weighs 8 kg, while the complete wheel weighs between 16 and 22 kg, depending on its load rating.
Performance and Material Considerations
The developer reports operation across temperatures from −30°C to +40°C and describes the tyres as proven in battlefield conditions. These are company-reported performance claims; the supplied project information does not include detailed test methods or independent validation.
For automotive and product designers, the project illustrates how additive manufacturing can integrate cushioning and load-bearing functions into a printed polymer structure. Its environmental performance, however, remains unquantified. The supplied information does not specify recycled or biobased content, service life, recyclability or lifecycle impacts. These factors would be needed to assess any sustainability benefits alongside the intended improvements in operational reliability.
Source & photos: Print&Live / iSCALE3D