Reinventing the wheel: Tech drives tyre innovation

The race to create high-performance, eco-friendly tyres has never been more intense. As the automotive industry moves towards sustainability, premium tyre manufacturers are leveraging cutting-edge technology to improve durability and efficiency, and reduce environmental impact.

By integrating artificial intelligence (AI), advanced materials science, and 3D metal printing, manufacturers are redefining how tyres are designed, produced, and ultimately disposed of. These innovations are not only improving road performance but also ensuring consistency from the first to the last millimetre of tread wear.

The future of tyre design

The digital transformation of the automotive industry has had a profound impact on tyre manufacturing. AI-driven models are now at the core of product development, streamlining the traditional trial-and-error approach. Instead of relying solely on physical prototypes, manufacturers like Hankook have adopted virtual tyre modelling, where computer simulations predict a tyre’s performance based on past data, physical parameters, and AI algorithms. This significantly reduces development time and costs, while enhancing precision.

One of the most crucial aspects of tyre production is the compound formulation, which determines performance characteristics such as grip, wear resistance, and rolling efficiency. Hankook’s Virtual Compound Design (VCD) technology utilises AI to predict compound properties and optimise material combinations. By conducting virtual simulations on cloud platforms, the system refines formulas without requiring extensive physical testing. This approach not only accelerates development but also improves the sustainability of the process.

Bridgestone, another industry leader, has also integrated AI into its manufacturing processes. The company employs Smart Strain Sensor Technology, which analyses tyre deformation in real time to optimise tread design. By collecting and processing vast amounts of data, Bridgestone enhances performance consistency, ensuring tyres maintain their integrity under different driving conditions.

Sustainable tyres for a greener future

As the world shifts towards environmentally conscious solutions, tyre manufacturers are rethinking their material strategies. Hankook’s E.Circle initiative is a prime example, committing to a fully sustainable product line by 2050. Currently, around 30% of the materials in Hankook’s latest truck and bus tyres are derived from sustainable sources such as natural rubber, reclaimed rubber, and recovered carbon black.

Expanding on this vision, the company is experimenting with bio-fillers made from recycled agricultural waste and International Sustainability and Carbon Certification (ISCC)-certified synthetic rubber derived from post-consumer plastics. These developments align with upcoming Euro 7 legislation, which will regulate tyre and road wear particles (TRWP) based on wear rate. With the rise of electric trucks and buses, which place greater stress on tyres due to their weight, compound development is being tailored to improve wear resistance and reduce rolling resistance.

Michelin has also been at the forefront of sustainable tyre innovation. The company’s VISION concept tyre is an airless, biodegradable prototype made entirely from renewable materials. Michelin is exploring the use of orange peels, wood chips, and even algae in rubber production, aiming to reduce reliance on fossil fuel-based materials while maintaining high-performance standards.

Revolutionising tread design

One of the most remarkable advances in tyre technology is the use of 3D metal printing to create complex tread moulds. This innovation allows manufacturers to incorporate intricate, performance-enhancing features that were previously impossible to produce.

Hankook has leveraged 3D printing to develop hidden grooves and tread patterns that only reveal themselves as the tyre wears down. These hidden features help strengthen the tread block by locking together different sections when in contact with the road, reducing heat generation and improving wear resistance. This results in lower rolling resistance, which enhances fuel efficiency and extends mileage. Additionally, as the tread wears, new gripping surfaces and water evacuation channels emerge, ensuring consistent traction even when the tyre is significantly worn.

Recognising the potential of this technology early on, Hankook began researching 3D printing for tread mould production in 2013. Today, the company uses the approach extensively in premium tyre development, ensuring improved durability and adaptability.

Other manufacturers, such as Continental, have also integrated 3D printing into their production lines. Continental’s Taraxagum project explores the use of dandelion rubber in combination with 3D-printed tread patterns. This approach not only enhances grip and longevity, but also reduces dependency on traditional rubber plantations, which are often linked to deforestation.

Technology-driven performance gains

The combination of AI, sustainable materials, and 3D printing has led to significant improvements in tyre performance. Hankook has reported that its latest generation of tyres achieves up to 20% better performance compared to previous models. More than 80% of the company’s European sales now come from tyres introduced in the past three years, demonstrating the rapid pace of innovation in the sector.

These advancements are particularly crucial in the era of electric vehicles (EVs). EVs require tyres with superior wear resistance and lower rolling resistance, due to their heavier weight and higher torque. By incorporating advanced tread designs, AI-driven compound optimisation, and sustainable materials, tyre manufacturers are now addressing these challenges while enhancing overall road safety.

The role of ISCC-certified synthetic rubber

A key component of the sustainability movement in tyre manufacturing is the adoption of ISCC-certified synthetic rubber. The ISCC ensures that raw materials are sourced responsibly and that carbon emissions are minimised throughout the production process.

ISCC-certified synthetic rubber offers multiple benefits, including:

• Sustainability: It is produced using feedstocks derived from post-consumer plastics, reducing reliance on fossil fuels.
• Traceability: A verified chain of custody ensures transparency, from raw material sourcing to final product.
• Carbon Reduction: Lower emissions during production contribute to a reduced environmental impact.
• Market Advantage: With consumers and industries prioritising sustainability, ISCC certification enhances the appeal of eco-friendly tyre products.

Manufacturers such as Pirelli have embraced ISCC-certified synthetic rubber to align with their carbon-neutral goals. Pirelli’s latest tyres incorporate bio-based materials and renewable rubber blends, setting new industry benchmarks for sustainable performance.

Tyre innovation: the road ahead

The tyre industry is undergoing a transformation driven by cutting-edge technology. AI-powered design, sustainable material integration, and 3D printing are revolutionising the way tyres are developed, enhancing both performance and environmental responsibility. As regulations become stricter and EV adoption accelerates, manufacturers must continue pushing the boundaries of innovation.

With sustainability at the forefront, the future of tyres is no longer just about grip and durability – it is about creating products that tread lightly on the planet while delivering unparalleled performance. The next generation of tyres will not only help vehicles move more efficiently but will also play a crucial role in building a cleaner, more sustainable world.