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.

Watch Phase 2 photos & videos on the right

Following rigorous lab validations the airless UTV tires underwent extreme cold weather field testing on rugged trails 5 to 10 degrees below freezing. The team evaluated tire compression and a new chunky tread pattern on snow, smooth rocks, and sheet ice. Despite the inability to "air down" the stiff rubber the tires demonstrated exceptional traction and durability without failure. Conquering these harsh winter conditions ensures highly confident performance in warmer environments.

Watch Phase 3.1 photos & videos on the right

During the Custom Built SxS phase the R'n'D team faced the immense challenge of customizing a Can-Am Maverick UTV. Taking on this second major project created a high-pressure race to prepare the machine for ConExpo 2026. Customization involved completely stripping down the UTV leaving it with noticeably missing parts as they prepped it for a new paint job. Despite the massive hurdle of juggling two builds simultaneously the team pushed their timeline to the limit to finish the custom SxS for the expo.

Watch Phase 3.2 photos on the right

At ConExpo 2026 Evolution Wheel displayed prototype airless UTV tires on a custom Can-Am to gather valuable customer feedback. Though not yet for sale, the current tread provides exceptional traction. To perfect the design the tires will undergo rigorous off-road endurance testing right after the show including a Vegas to Reno run and slick-rock crawling in Moab. By publicly sharing this hands-on testing process, the company is transparently refining the prototypes for the market.

Watch Phase 3.3 photos & videos on the right

During their off-roading trip to Sand Hollow, the side-by-side (UTV) proved highly capable, easily navigating a challenging technical level eight rock-crawling trail. The vehicle is equipped with unique solid modular tires that the team is actively testing and "dialing in" to achieve the proper compression. These solid tires feature a highly adaptable sectioned design meaning individual parts can be easily fixed or swapped out as needed. Because of this modularit, the tires can also be customized for specific terrains such as unbolting half of the sections to install sand paddles that are capable of throwing a 40-foot rooster tail of sand.

Watch Phase 3.4 photos on the right

The Vegas to Reno 500 served as a crucial real-world testing ground during the development phase of our solid, airless UTV tires. To aggressively prove this technology on video the R'n'D team equipped a Can-Am side-by-side for an unprecedented 500-mile off-road endurance challenge. Navigating harsh desert terrain past Sawtooth Mountain in 80 to 85-degree heat, this grueling run pushed the absolute limits of the airless design allowing us to gather essential performance data and dial in the tires for future iterations.

Watch Phase 3.5 photos & videos on the right

After enduring 225 miles of harsh off-road trails our 29x9 airless UTV tires set a side-by-side world speed record of 81 mph on the Mud Lake salt flats using a stock Can-Am Maverick DS. The vehicle's stock belt and clutch system caused a bottleneck burning and losing power at top speed. Our development roadmap focuses on breaking the 100 mph mark by upgrading to a larger gear-driven or clutch-driven machine such as a Can-Am RR and testing it at the Bonneville Salt Flats during official speed trials.

Watch Phase 3.6 photos & videos on the right