Document authentic UTV operating conditions across target applications. Recreational trail riding, agricultural work, utility tasks, and extreme terrain use. Quantify load profiles (static, dynamic, and impact), speed ranges (crawl to maximum rated), terrain variables (rock, mud, sand, hardpack, obstacles), and environmental factors. Translate operational data into measurable design targets. Lock down hard constraints early, rim diameter and width compatibility, hub bearing clearances, brake caliper/rotor interference zones, suspension travel envelopes, and vehicle weight distribution. Ensure all design work occurs within these non-negotiable boundaries to prevent costly late-stage redesigns.

Determine the appropriate segmented architecture, interlock configuration, attachment method, and candidate material systems for the UTV airless tire. Develop CAD models and conduct finite element simulations to evaluate stress distribution, strain behavior, contact pressure profiles, and thermal rise under defined worst-case duty cycles. Perform iterative design refinements until the computational model demonstrates compliance with all performance requirements and maintains acceptable safety margins.

Fabricate initial tire segments and rim assemblies using prototype tooling to validate core design assumptions. Conduct laboratory testing for load capacity, structural durability, thermal performance, chip and cut resistance, torque retention, and balance characteristics. Analyze test data to refine geometry, material compounds, and service procedures prior to initiating field evaluations.