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Tweel

The Tweel is an innovative airless tire design developed by the French tire manufacturer Michelin, functioning as a single integrated unit that combines the tire and wheel to eliminate the need for inflation, inner tubes, or air pressure maintenance.^[1] Introduced commercially in 2012, the technology features a rubber tread attached to a hub via flexible poly-resin spokes that absorb shocks and provide load support, mimicking the ride characteristics of pneumatic tires while preventing flats and reducing downtime.^[1] Conceived in the late 1990s by Michelin engineers Dr. Tim Rhyne and Steve Cron at the company's research center in Greenville, South Carolina, the Tweel—short for "tire wheel"—received patents between 1999 and 2003, with an early prototype unveiled in 2005.^[1] This non-pneumatic structure relies on a shear beam design where the spokes deform under load to adapt to terrain, offering enhanced traction, stability, and a smoother ride compared to traditional solid or air-filled tires.^[1] Key advantages include a lifespan two to three times longer than pneumatic equivalents, lower vibration and bounce for operator comfort, and no risk of punctures, making it particularly suitable for demanding environments.^[1]^[2] The Tweel has found primary applications in commercial turf care equipment, such as zero-turn radius mowers, where it maintains consistent height and protects grass surfaces; skid steer loaders for construction and landscaping; and utility vehicles like ATVs, UTVs, golf carts, and military machinery.^[1]^[2] Michelin continues to expand the Tweel lineup under the X Tweel brand, focusing on radial constructions for improved durability and performance across various sizes and terrains.^[2]

History

Invention and Early Development

The Tweel was invented in the late 1990s by Michelin engineers Dr. Timothy B. Rhyne and Steven M. Cron, who sought to address the limitations of traditional pneumatic tires by developing an airless alternative that eliminates the risk of catastrophic failure due to punctures or loss of air pressure.^[3]^[4] Initial prototype development occurred at Michelin's Americas Research and Development Corporation (MARC) in Greenville, South Carolina, where the team focused on proving the feasibility of a non-pneumatic tire design capable of supporting vehicle loads through flexible structural elements rather than compressed air.^[5] This work built on earlier explorations of run-flat tire concepts dating back to the late 1990s, but shifted toward a fully airless system to enhance durability and reduce maintenance needs.^[6] The Tweel made its public debut at the 2005 North American International Auto Show in Detroit, where Michelin demonstrated a prototype on Segway's Concept Centaur, a four-wheeled personal mobility vehicle, and the iBOT wheelchair, highlighting its ability to absorb shocks and maintain performance without air.^[7]^[8] The unveiling generated significant interest in the technology's potential to revolutionize tire design. Early recognition followed swiftly, with Popular Science naming the Tweel the top innovation in its Automotive Technology category for the 2005 "Best of What's New" awards.^[9] It was also featured among TIME magazine's Most Amazing Inventions of 2005. In 2006, the Tweel received the Intermat Gold Medal for Innovation from the Paris-based construction equipment trade show.^[10] For their contributions to non-pneumatic tire technology, Rhyne and Cron were jointly awarded the Charles Goodyear Medal by the Rubber Division of the American Chemical Society in 2022.^[11] These accolades underscored the Tweel's breakthrough status and paved the way for its commercialization beginning in 2012.^[1]

Commercialization and Recent Expansions

The first commercial Tweel product, the Michelin X Tweel SSL in size 12N16.5, was launched in July 2012 specifically for skid-steer loaders, marking the transition from prototype to market availability and establishing Michelin's strategy of targeting high-downtime applications in construction and material handling.^[12] This airless radial tire addressed common issues like punctures and maintenance, enabling broader adoption in rugged environments. In recognition of its innovative commercialization, the X Tweel SSL received the Silver Edison Award in the Transportation category on April 26, 2013, highlighting its impact on reducing operational downtime.^[13] Michelin expanded the Tweel line to lawn mowers and turf applications starting in 2014–2015, with the X Tweel Turf tire becoming available for zero-turn radius mowers and forming a key partnership with John Deere for integration on ZTrak series equipment.^[14]^[15] This move broadened market reach into landscaping and grounds care, emphasizing turf-friendly designs that maintained even cuts and reduced bounce. By 2019, Michelin announced three new Tweel models for mowers, including the 15x6N6 X Tweel Turf Caster tire, aimed at larger diesel zero-turn mowers and set for release in early 2020, further solidifying adoption in commercial turf management.^[16] From 2023 to 2025, Michelin continued expanding the X Tweel portfolio, introducing the SSL 2 series with an All Terrain tread pattern in March 2024 for skid-steer loaders, featuring enhanced traction for off-road use and integration with a new wheel system developed by moveero.^[17]^[18] The line also extended to utility task vehicles (UTVs) with models like the 26x9.00N14, alongside caster wheel options for mowers, though caster models faced backorder issues starting in early 2025 due to high demand, with restocking anticipated by late fall 2025 as of September 2025 (though some delays to spring 2026 were reported and partial availability has resumed).^[19] These developments have driven growing market adoption, as evidenced by the broader airless tire sector's expansion at a compound annual growth rate of approximately 6% through 2025, with Tweel contributing to increased productivity in construction, agriculture, and recreational applications.^[20]

Design and Technology

Core Components

The Tweel, a portmanteau of "tire" and "wheel," represents a single integrated assembly that combines these elements into one non-pneumatic unit, eliminating the need for a separate rim or inflation system.^[1] This design achieves airless functionality through a structural architecture that relies on mechanical deformation rather than compressed air, with flexible spokes providing load support and shock absorption akin to pneumatic cushioning.^[21] At the core of the Tweel is a series of polyurethane flexible spokes arranged in a hub-integrated configuration, which bear the vehicle's load in tension and flex to mimic the compressive behavior of air in traditional tires.^[1] These spokes connect a central reinforced steel hub to an outer shear beam, forming a cohesive structure without an inner tube or air chamber. The shear beam, an elastomeric component, absorbs shocks by deforming under load while preserving overall structural integrity during operation.^[21] The Tweel's outer layer consists of a replaceable rubber tread band bonded to the shear beam, allowing for targeted replacement of the wear surface without discarding the entire assembly.^[1] In terms of geometry, the spokes are engineered to flex radially to enhance ride comfort by distributing vertical impacts and circumferentially to facilitate torque transmission and handling stability, all within a fully enclosed, airless framework.^[21]

Materials and Manufacturing

The Tweel tire employs high-strength polyurethane, specifically a structural poly-resin formulation, for its flexible spokes, which deliver the necessary elasticity and resistance to fatigue under repeated loading. This material choice allows the spokes to absorb impacts and maintain structural integrity without the need for air pressure. The rubber tread, composed of specialized compounds, is engineered to provide traction and wear characteristics akin to those in conventional pneumatic tires, ensuring reliable grip across various surfaces.^[15]^[22] The hub is fabricated from heavy-gauge rigid steel to serve as a durable mounting point, while the shear beam incorporates reinforced elements such as proprietary Comp 10 Cable™, a steel cable composite, to handle tension and shear forces effectively. These components contribute to the Tweel's load-bearing capacity, for example, supporting rear axle weights up to 2,310 pounds in utility vehicle applications at speeds of 50 mph (with per-tire capacities varying by model, such as up to 3,700 pounds for larger skid-steer variants).^[15] Key aspects of the design, including the spoke geometry and assembly techniques, are protected under U.S. patents issued to Michelin starting in the late 1990s and early 2000s, such as those issued in 1999, 2000, and 2003 covering the integration of the hub, spokes, and shear band.^[15] Manufacturing begins with injection molding of the polyurethane spokes onto the hub and shear beam assembly, followed by the application of the rubber tread band using specialized adhesives for secure bonding. This process enables the modular replacement of the tread without disassembling the entire unit, enhancing serviceability and reducing downtime. Produced at Michelin's facility in South Carolina, the assembly adapts traditional tire curing methods alongside proprietary casting and injection techniques to ensure precision and scalability. As of October 2025, recent enhancements include an improved shear beam construction for extended core life and a new poly-resin spoke material offering up to 10 times greater spoke durability compared to earlier versions.^[23]^[15]^[24] From an environmental perspective, the Tweel design minimizes raw material consumption relative to pneumatic tires, with life-cycle assessments showing overall environmental savings of 2-6% across production, use, and end-of-life stages, primarily due to the elimination of inner liners and reduced need for replacements from punctures. The polyurethane spokes are recyclable, supporting Michelin's broader goals for sustainable material recovery in tire manufacturing. These attributes, combined with lower weight and no inflation-related waste, position the Tweel as a more resource-efficient alternative.^[25]^[25]

Performance Characteristics

Advantages

The Tweel tire's puncture-proof design eliminates the risk of flats from impacts or debris, significantly reducing downtime in commercial operations compared to conventional pneumatic tires. This airless structure, supported by flexible polyurethane spokes, maintains performance integrity without the need for repairs or replacements due to punctures.^[1] Due to the even distribution of load across the spokes and hub, the Tweel exhibits extended tread life, lasting 2-3 times longer than equivalent pneumatic tires at the same tread depth. This durability arises from the absence of sidewall flexing that causes uneven wear in air-filled tires, allowing for consistent performance over extended use.^[1] In terms of safety, the Tweel provides enhanced handling, stability, and comfort, with reduced bounce during operation that improves overall vehicle control. The poly-resin spokes absorb road shocks effectively, contributing to a smoother ride that matches or exceeds pneumatic tire performance in real-world conditions.^[1] As a maintenance-free option, the Tweel requires no air pressure monitoring, inflation adjustments, or complex mounting procedures, thereby lowering operational costs associated with tire upkeep and service interruptions. This single-unit assembly simplifies installation and eliminates common issues like unseated beads or slow leaks.^[1]^[2] Environmentally, the Tweel's longevity reduces the frequency of tire replacements, minimizing waste and resource consumption over its lifecycle. Additionally, its design can lower rolling resistance, leading to modest improvements in fuel efficiency during use.^[1] Refinements introduced after 2013 have addressed early concerns with vibration and noise, enabling the Tweel to deliver ride quality comparable to pneumatic tires through optimized spoke architecture that dampens impacts and transfers energy efficiently.^[15]

Disadvantages

Despite its advantages, such as resistance to punctures, the Tweel airless tire presents several disadvantages that limit its adoption in certain applications. One primary drawback is the higher initial cost, which can be 2-3 times that of equivalent pneumatic tire and wheel assemblies, attributed to the intricate manufacturing process required for the integrated polyurethane spokes and hub.^[26] This elevated price point, often exceeding $600 per unit for common sizes like 24x12N12, makes it less accessible for budget-conscious users despite longer tread life.^[27] The Tweel's design also results in increased weight compared to traditional pneumatic setups, with models such as the 26x12N12 weighing approximately 60 lbs, roughly 20-50% more than a comparable pneumatic tire (around 30 lbs) plus rim assembly, potentially reducing fuel efficiency and maneuverability in lightweight vehicles like small UTVs or mowers.^[28]^[29] Early prototypes of the Tweel, particularly those developed before 2013 for automotive use, suffered from excessive noise and vibration caused by spoke resonance at higher speeds, issues that were addressed in later redesigns.^[15] Additionally, the Tweel's size range remains limited, primarily suited for off-road, low-speed applications such as zero-turn mowers and UTVs with maximum speeds around 25 mph, and it has not yet been fully scaled for high-speed passenger car use due to ongoing challenges with heat buildup and stability.^[30] Repairing the Tweel is challenging, as damage to the flexible spokes from impacts often necessitates full unit replacement if more than 20% are affected, although such failures are rare in normal operation.^[31] In 2025, supply chain disruptions have led to backorders for certain caster wheel models, with delays extending into late fall or even spring 2026, affecting availability for mower maintenance.^[19]

Applications

Commercial Uses

The Michelin X Tweel SSL airless radial tire, available in models such as the 12N16.5, has been widely adopted for skid-steer loaders in construction and landscaping since its commercial launch in July 2012, providing reliable traction on rough terrain without the risk of flats.^[32]^[33] These integrated tire-wheel assemblies are factory options on brands like CASE skid-steer loaders, enhancing productivity in demanding environments by eliminating downtime associated with pneumatic tire maintenance.^[34] In the lawn and turf maintenance sector, the Michelin X Tweel Turf has become a standard for zero-turn mowers, particularly through its integration with John Deere equipment starting in 2015, where it minimizes turf damage via a consistent footprint and even weight distribution.^[35]^[36] This airless design supports precise cutting on golf courses, sports fields, and residential properties by preventing ruts and ensuring stable operation over varied grass surfaces.^[37] For recreational and agricultural applications, all-terrain models like the 26x9.00N14 Michelin X Tweel UTV, launched in 2018, equip utility terrain vehicles (UTVs) and all-terrain vehicles (ATVs) for off-road use in farming and leisure activities.^[38]^[39] These tires offer durability on rugged paths, supporting loads in low-speed operations without air pressure concerns.^[40] Caster wheel variants of the Tweel, such as the 13x6.5N6 model, are applied in utility vehicles including golf carts and front-mounted on zero-turn mowers, with production expansions noted in 2025 amid high demand leading to backorder delays into late fall.^[19]^[41] This growth reflects increasing commercial reliance on Tweel technology in North America for low-speed, high-durability scenarios across landscaping and light construction industries.^[1] The Tweel technology has also undergone NASA testing for potential use in specialized lunar rover applications, informing its robust design for extreme conditions.^[42]

Research and Specialized Uses

The Tweel technology was developed for medical devices to enhance mobility in challenging terrains, notably Dean Kamen's iBOT wheelchair from the 2000s. This powered mobility system, designed for wheelchair users, was tested with Tweel wheels to enable all-terrain navigation, including climbing stairs and traversing uneven surfaces without punctures, providing greater independence for users with disabilities.^[43]^[44] In military and robotics applications, the Tweel has supported prototype development for dynamic stabilization and extreme environments. It was fitted to the Segway Centaur, a four-wheeled concept vehicle unveiled in 2005 that combines self-balancing technology with ATV-like capabilities, demonstrating potential for versatile robotic mobility.^[45]^[44] Additionally, a Tweel-derived Michelin Lunar Wheel was tested on NASA's Scarab rover prototype in late 2008, including field trials in Hawaii simulating lunar regolith, to evaluate performance for Moon and Mars exploration rovers under low-gravity and abrasive conditions.^[46]^[42] Experimental demonstrations of the Tweel have featured on concept all-terrain vehicles (ATVs) and utility vehicles at major auto shows, showcasing its adaptability beyond standard applications. For instance, at the 2005 North American International Auto Show in Detroit, prototypes equipped with Tweel tires highlighted their puncture-resistant performance on rough prototypes, influencing further innovation in off-road vehicle design.^[6] As of 2025, Michelin continues collaborative research on Tweel variants for off-road robotics and testing in extreme conditions, building on prior prototypes to advance durability in rugged, non-commercial scenarios such as robotic exploration platforms.^[1] In recognition of its innovative potential, the Michelin X Tweel received an honorable mention in the Automotive/Transportation category of the 2015 Create the Future Design Contest, sponsored by Tech Briefs Media Group and COMSOL, for advancing airless tire solutions in specialized mobility.^[47]

Uptis

The Uptis, or Unique Puncture-proof Tire System, is an airless tire prototype developed by Michelin as an evolution of its Tweel technology specifically adapted for passenger vehicles. Unveiled in 2019 at the Movin'On Summit in collaboration with General Motors, the Uptis builds on the original Tweel spoke concept by incorporating flexible composite spokes made from rubber and fiberglass-reinforced resin to support vehicle loads without compressed air.^[48]^[49] Key adaptations in the Uptis include lighter-weight spokes optimized for on-road durability and highway performance, enabling speeds up to 130 mph (209 km/h), a significant improvement over the Tweel's lower-speed limitations for off-road applications. The design features an integrated wheel assembly that enhances weight reduction and recyclability, with initial road testing conducted on Chevrolet Bolt EV vehicles to assess real-world handling and efficiency. Unlike the heavier Tweel suited for construction equipment, the Uptis prioritizes lower overall weight and puncture resistance for urban electric vehicles and autonomous robotaxis, potentially reducing tire waste by eliminating flats and enabling longer service life.^[50]^[51]^[52] Michelin has partnered with General Motors since 2019 to refine the Uptis through extensive testing, including fleet trials on Bolt EVs to evaluate integration with electric drivetrains. In 2023, Michelin expanded real-world validation by equipping nearly 50 DHL Express delivery vans in Singapore with Uptis prototypes for urban logistics operations, focusing on durability and reduced downtime. These partnerships derive from Michelin's foundational Tweel patents, adapting the airless architecture for scalable passenger car use while maintaining core puncture-proof benefits.^[53]^[54] The Uptis received the Tire Technology of the Year award at the 2020 Tire Technology International Awards for Innovation and Excellence, recognizing its advancements in sustainable mobility. As of November 2025, the technology remains in the prototype phase with no commercial launch, delayed from an initial 2024 target due to ongoing refinements in performance and regulatory compliance. Michelin continues road testing with partners like DHL and La Poste, but the Uptis has not yet achieved homologation for consumer vehicle use, pending international standards for airless tires. Recent discussions with Tesla for potential testing underscore its targeting of urban EVs and robotaxis, with mass-market availability projected later in the decade.^[55]^[56]

Other Airless Tire Innovations

Bridgestone Corporation introduced the Air Free concept in 2017 as an airless tire technology utilizing a flexible spoke structure made from thermoplastic resin to support vehicle weight without inflation.^[57] This design, featuring spokes arranged in a honeycomb-like pattern, was initially targeted for bicycles and light vehicles to eliminate puncture risks and maintenance needs.^[58] The technology achieved commercialization in 2019, with tires deployed for bicycles during the Tokyo 2020 Olympic and Paralympic Games, where they supported barrier-free transport vehicles in the athlete village.^[59] In 2016, Goodyear unveiled the Eagle-360, a conceptual spherical airless tire designed for urban electric vehicles and autonomous cars, suspended via magnetic levitation to enable omnidirectional movement.^[60] This prototype integrates biomimetic principles, with a tread pattern inspired by gecko feet for enhanced grip on wet surfaces, and relies on electromagnetic fields similar to maglev systems for wheel attachment, improving maneuverability in congested city environments.^[61] While not yet in production, the Eagle-360 represents an innovative shift toward spherical geometries that could reduce rolling resistance in low-speed urban applications.^[62] As of 2025, advancements in additive manufacturing have led to BigRep's development of 3D-printed airless tires for electric motorcycles, featured in their NERA e-motorbike project.^[63] These tires use flexible thermoplastic filaments to create customized tread patterns and structural supports, with the front tire incorporating an arch design for smoother rides and the rear featuring hexagonal elements for traction.^[64] This approach allows for rapid prototyping and on-demand customization, addressing limitations in traditional molding for niche vehicles. Major tire manufacturers, including Goodyear and Bridgestone, have pledged commercial airless tire entries for passenger vehicles by 2030, driven by commitments to sustainable mobility solutions.^[65] Industry-wide challenges in airless tire adoption include scaling designs for high-speed operations, where spoke structures can generate excessive noise and heat buildup, potentially compromising ride comfort and durability.^[66] Production costs remain elevated due to advanced materials like composites and resins, hindering mass-market viability despite environmental benefits such as reduced material waste and recyclability.^[67] These innovations align with broader sustainability goals, as airless designs minimize resource use in manufacturing and eliminate disposal issues from pneumatic tire waste.^[52] Comparisons across airless technologies highlight differences between non-spoke designs, such as solid rubber variants that offer puncture resistance but limited shock absorption, and flexible spoke systems akin to the Tweel, which provide better compliance and load distribution through deformable polyurethane or resin spokes.^[67] No direct licensing or technology transfers have been reported among these competitors, fostering independent evolution in the sector.^[21]

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Apr 22, 2024 · Michelin is continuing to test and develop its Uptis airless tires as a necessary part of the future.
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Michelin, GM Take the Air Out of Tires for Passenger Vehicles
Jun 4, 2019 · Uptis features ground-breaking improvements in architecture and composite materials, which enable Uptis to bear the car's weight at road-going ...Missing: lighter Chevy
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DHL begins pilot program using Michelin UPTIS airless tires
Jan 13, 2023 · Michelin has partnered with DHL for on-road trials of the Michelin UPTIS airless tire. Nearly 50 DHL Express vans will begin running on the ...
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Whatever happened to the amazing airless tyre? - Yahoo! Autos
Jan 28, 2025 · In late January a Michelin spokesman said there were no immediate plans to market the Uptis tyre since they were still being tested by DHL and ...
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https://www.notateslaapp.com/news/2090/tesla-in-talks-with-michelin-to-test-new-airless-tires
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Bridgestone's Non-Pneumatic Tire Technology “Air Free Concept”
The “Air Free Concept” is a technology that eliminates the need for tires to be inflated with air to support the weight, using a unique structure of spokes.Missing: honeycomb Tokyo Olympics 2019
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bridgestone's air-free bicycle tires let you wave goodbye to punctures
Apr 20, 2017 · the company set out to make the bicycle tire available in 2019, just in time for the tokyo olympics in 2020. in the future, the japanese ...Missing: honeycomb commercialization
[59]
Bridgestone solutions helping to keep Tokyo 2020 moving safely ...
Jul 31, 2021 · These non-pneumatic tyres feature a unique structure of spokes that eliminates the risk of a flat and the need to be inflated with air. Made ...Missing: honeycomb commercialization 2019
[60]
Goodyear Reveals Concept Tires for Autonomous Cars - Mar 1, 2016
Mar 1, 2016 · The Goodyear Eagle-360 is a spherical-shaped design concept tire that would provide self-driving cars ultimate maneuverability, connectivity and biomimicry to ...Missing: urban EVs
[61]
Goodyear reveals spherical tyres for self-driving cars - Dezeen
Mar 9, 2016 · Each spherical tyre would be suspended from the car by magnetic fields – using similar technology to magnetic levitation (maglev) trains.
[62]
Goodyear Shares Concepts, Technology for Urban Mobility at ...
Mar 7, 2017 · The Eagle 360 Urban is an evolution of Goodyear's 2016 spherical-shaped design concept for autonomous vehicles, further integrating the tire ...Missing: magnetic levitation
[63]
NERA: World's first 3D printed E-Motorcycle - BigRep
Airless tires with customized tread printed with flexible thermoplastic; Front tire has an arch structure for a softer, smoother ride; Back tire has a ...
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BigRep 3D Prints World-First Airless Tires for Motorcycles
Jan 6, 2025 · Michelin and General Motors recently unveiled their brand-new 3D printed Uptis airless tire prototype at the at the Movin'On Summit for sustainable mobility.
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Goodyear: Airless tires could be commercial ready by 2030
May 31, 2022 · Goodyear has set a goal of having an airless passenger tire/wheel commercially ready by 2030, company officials signaled at a recent press event.
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Airless tires: a disruptive revolution in the tire industry
Jul 16, 2024 · Due to the limitations of materials and structure, airless tires will make a lot of noise when driving at high speeds and the ride comfort will ...
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https://monstertires.com/airless-tire-tech-construction/