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An airless tire has been 3D printed on a BigRep 3D printer (Germany). You can leave your bike pump at home, because you probably won’t need it anymore. This is one of the new uses of rapid prototyping technology as it moves into real production to meet growing user demand.
A 3D printed tire that will never go flat
This is a special tire. It is made with 3D printing, never loses air, and still gives a smooth ride. Leave the bike pump at home. You won’t need it once you have the 3D printed airless tire from a German startup team.
BigRep, a startup based in Berlin, Germany, has proposed a set of airless bicycle tires made with 3D printing. BigRep test-rode a bike fitted with these tires to show the public what they can do.
- See also: SLA rapid prototyping 3D printers
The design is similar to Michelin’s airless concept tire. BigRep replaces the air inside the tire with a complex support structure, in this case a three-layer honeycomb. The pattern and density of this support layer can be changed to suit the type of bike, such as a mountain bike or a racing bike.
This prototype tire is said to be good enough for everyday city cycling.
Video of BigRep’s 3D printed airless tire. The BigRep 3D printer is a large-format 3D printer with a build size of up to 1 meter. This huge industrial 3D printer was developed in Germany and serves the needs of businesses around the world.
Source: TXL/DKN/Vnexpress
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How does an airless tire work?
A conventional tire relies on compressed air inside it to carry the load and absorb shocks. An airless tire replaces the air with an elastic structure, usually spokes or a honeycomb, that connects the rim to the tread. When the wheel rolls over a bump, the spokes or cells flex and spring back, which cushions the ride much like an air cushion. The biggest advantage is that the tire can’t puncture and never needs pumping. That makes it a good fit for city bikes, small electric vehicles and carts used inside factories.
Why is 3D printing a good fit for developing airless tires?
Honeycomb and elastic lattice structures have complex geometry that is hard to make with traditional molding during the testing stage. With 3D printing, engineers can change the cell density, wall thickness and spoke shape, then print and test right away. This cuts the design loop a lot. The main benefits are:
- Stiffness can vary by zone by adjusting the structure density, with no need to change materials.
- Many design options can be tested in a short time without making molds.
- The tire can be tuned to its use: a mountain bike needs comfort, a racing bike needs stiffness and low weight.
- Small batches can be produced and personalized for each rider.
Common materials and printing technologies
3D printed airless tires usually use elastic materials such as TPU (flexible plastic) on FDM printers, or elastic powders on sintering technologies. FDM with TPU works well for prototypes and low-volume parts. Powder-based processes produce more uniform parts, need no support material and handle complex lattices well. Whatever the technology, a 3D printed tire still needs testing for fatigue life, grip and heat resistance before real-world use.
Lessons for manufacturers
The airless tire shows that 3D printing is not only for display models. It is also a tool for developing functional products. Elastic parts such as pads, gaskets, grips and shoe soles can be tested the same way. If you are developing rubber or flexible plastic parts that need fast prototypes, take a look at CT3D’s 3D printing service or call/Zalo 0975 008 728.
Frequently asked questions
Is a 3D printed airless tire as durable as a regular rubber tire?
Right now most 3D printed tires are still in testing or used for special purposes. Durability depends heavily on the material, the structural design and the operating conditions. Traditional vulcanized rubber tires still have the edge in grip and service life for normal use.
Can I print a bicycle tire at home on an FDM 3D printer?
Technically you can print one with TPU filament, but you need a printer that handles flexible filament well and a suitable structural design. A home-printed tire should only be used for testing. Don’t use it at high speed or with heavy loads, because it has not been safety tested.
What is TPU and why is it used for 3D printed tires?
TPU is a thermoplastic elastomer with properties close to rubber: it is flexible, wear resistant and springs back well. TPU can be printed on FDM machines, which makes it convenient for testing soft parts such as tires, pads and gaskets.
Can 3D printing replace mass tire production?
Not in the short term. 3D printing suits design, testing and small custom batches. For high volumes, traditional molding is still far cheaper per part.
Related services at CT3D Group
- On-demand 3D printing service
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