Capture the real use cases, loads, speeds, terrains, and service needs. Convert this into clear targets for safety, durability, heat, balance, cost, and serviceability. Agree on constraints like rim, hub, and brake clearances so the team designs to reality.

Choose the segmented architecture, interlocks, attachment method, and candidate materials. Use CAD and simulations to predict stress, strain, contact pressure, and heat rise under the worst duty cycles. Iterate until the virtual model meets the targets with acceptable margins.

Build initial tire segments and rims with prototype tooling to verify structural fundamentals. Subject the prototypes to extreme dynamometer evaluations, precision wheel balancing, and controlled explosion testing alongside standard bench tests for load, heat, and cut resistance. Leverage these results to refine geometry, material compounds, and service procedures before field deployment.

Watch Phase 2 videos on the right

Following rigorous lab validations, the airless off-road truck tires underwent extreme cold weather field testing on rugged terrain well below freezing. The engineering team conducted critical brake tests on a Chevy Colorado to evaluate stopping distances on sheet ice and packed snow. Furthermore, the prototypes endured extreme winter tests on a fully loaded Humvee to assess spoke compression and structural durability under heavy tactical payloads. Despite the inability to air down for a wider footprint, the robust composite structures delivered exceptional traction without failure. Conquering these harsh environments ensures highly confident performance across all temperature ranges.

Watch Phase 3.1 Videos and Photos on the Right

In this phase, we built a fully customized Humvee as a physical "business card" for ConExpo to showcase our complete in-house manufacturing capabilities. Stripping the vehicle down to the tub our team handled every detail fabricating custom doors, rock sliders, and an old-school 80s-style light bar. By managing all the painting, powder coating, and even redesigning the custom bumper ourselves, this hands-on build proves our advanced design and fabrication skills as we finalize the platform for our prototype tires.

Watch Phase 3.2 photos on the right

For our ConExpo 2026 debut we have mounted our airless off-road prototypes on a custom Humvee built entirely in-house. This vehicle serves as a physical demonstration of our manufacturing capabilities which range from robotically welded rims to custom-mixed rubber compounds. To ensure these tires survive the most demanding environments, we are validating heavy duty durability through extreme stress testing. At the booth, the Humvee is displayed crawling over obstacles to show attendees real-time compression and ruggedness.

Watch Phase 3.3 Videos and Photos on the Right

Deploy the airless prototypes on the Humvee platform to the technical sandstone of Sand Hollow to validate heavy duty durability through high-torque rock crawling. Monitor carcass deformation on slickrock and thermal stability across deep sand dunes. Execute field-side segment replacements to test maintainability while tracking fatigue against all off-road KPIs. Freeze the final design once this desert field data confirms the system satisfies all reliability standards.

Watch Phase 3.4 photos and videos on the right