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The Tweel airless tire design

The Tweel (a portmanteau of tire and wheel) is an airless tire design developed by the French tire company Michelin. Its significant advantage over pneumatic tires is that the Tweel does not use a bladder full of compressed air, and therefore cannot burst, leak pressure, or become flat. Instead, the Tweel's hub is connected to the rim via flexible polyurethane spokes which fulfil the shock-absorbing role provided by the compressed air in a traditional tire.

Design

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The Tweel consists of a band of conventional tire rubber with molded tread, a shear beam just below the tread that creates a compliant contact patch, a series of energy-absorbing polyurethane spokes, and an integral inner hub structure. Both the shear beam and the polyurethane spokes can be designed to provide a calibrated directional stiffness in order to control both how the Tweel handles and how it handles loads. The inner hub structure may be either rigid or compliant,[1] depending on the application requirements, and as such may contain a matrix of deformable plastic structures that flex under load and subsequently return to their original shape. By varying the thickness and size of the spokes the design elements can be manipulated to engineer a wide range of ride and handling qualities. The tread can be as specialized as any conventional tires and is replaceable.[2]

Benefits and drawbacks

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Potential benefits of the Tweel include not only the obvious safety and convenience of never having flat tires, but also, in automotive applications, the Tweel airless tire has the potential to be able to brake better – a significant performance compromise that is inherent to pneumatic tires. Unlike a pneumatic tire, a Tweel can be designed to have high lateral stiffness while simultaneously having low vertical stiffness. This can be achieved because, in the design elements of a Tweel, the vertical and lateral stiffness are not inseparably linked and can thus be optimized independently. Because there is no air bladder under the tread, tread patterns can, if desired, even incorporate water evacuation through holes in the design thus eliminating or significantly reducing hydroplaning. Michelin expects the tread to last two to three times as long as a conventional tire.[3] Because the tread rubber around the outer circumference is replaceable when worn (as opposed to disposing of a whole worn tire), the potential environmental impact of a Tweel airless tire can be less than that of a conventional pneumatic tire.

Tweel is useful for: "vehicles that don't have suspensions like lawn mowers – those low speed specialty vehicles that don't have suspensions. The comfort is quite good and better than inflated tyres" said Terry K. Gettys, executive vice-president, research and development, and member of the group executive committee at French tire company Michelin.[4]

Military testing has indicated that the Tweel deflects mine blasts away from the vehicle better than standard tires and that the Tweel remains mobile even with several spokes damaged or missing.[citation needed]

Although it is acknowledged that the initial prototype automotive Tweel tires did demonstrate flaws with regard to noise and high-speed vibration[5] and produced 5 percent more friction compared to a radial tire,[3] these early issues were resolved in subsequent prototypes and, in 2013, automotive Tweel prototype products had been shown to be well-behaved and reliable. As a demonstration of Tweel viability and reliability, three highway-driven vehicles (a 2012 Honda CR-Z, a resto-modded 1955 Morris Minor Traveller, and an Aluma brand trailer hauling a Polaris ATV which was also equipped with Tweel tires) successfully participated in the entire 2013 Hot Rod Power Tour long-distance road trip event in June 2013.[6]

Applications

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The LRI AB Scarab Tweel

The iBOT mobility device and Segway's Concept Centaur were both introduced with Tweel airless tires. Michelin also has additional projects for the Tweel concept on small construction equipment, such as skid-steer loaders, for which it seems well suited.

NASA has contracted Michelin to develop a wheel for the next-generation lunar rover based on the Tweel concept.[7] This has resulted in the Lunar Rover Initiative AB Scarab wheels.[8]

In October 2012, Michelin North America Inc. began commercial sales of the Michelin 12N16.5 X Tweel for skid-steer loaders used in landscaping, construction, contracting, refuse/recycling and agricultural industries.[9]

Awards

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On 8 November 2005, Popular Science magazine named Michelin's Tweel as the "Best of What's New"[10] honor in the Automotive Technology category. The next day, Michelin NA was awarded a Hall of Fame Award by InnoVision[11] for continued leadership in innovation as evidenced by the development of the Tweel. TIME Magazine named the Tweel as "One of the Most Amazing Inventions of 2005"[12] a few short days later on 14 November 2005. The Intermat innovation commission in Paris (the International Exhibition of Equipment, Machinery and Techniques for the Construction and Building Materials Industry) awarded the Tweel with a 2006 Gold Medal for Innovation.[13] This prize reinforced Michelin's technological leadership and rewarded Michelin’s contribution to improvements in productivity and safety for the construction industry. The jury of Intermat 2006 was made up of recognized European experts and professionals and required to rank the innovations according to five criteria:

  • Technical design and technologies: improvement in productivity, ease of maintenance;
  • Economy: lower purchase price and maintenance costs;
  • Quality of work carried out;
  • Ease of use, ergonomics, comfort, safety and improvement in working conditions;
  • Environmental friendliness.

A Silver Award in the Transportation category was awarded to the Tweel SSL on 26 April 2013 by the 2013 Edison Awards.[14] Of the 7,156 applications received, 131 finalists were selected by the Edison Awards Committee. The Tweel SSL was one of 42 winners, who represented 12 categories and symbolize the persistence and excellence personified by Thomas Alva Edison. The Tweel SSL was selected as one of the 2013 Contractors’ Top 50 New Products[15] by readers of Equipment Today as one of the industry’s most innovative products for the year. In January 2014, Equipment World named one of the “five game-changing” construction products of 2013 for their 2014 Innovations Awards. The Tweel SSL was named as one of those five product winners.[16] The inventors of the Tweel, Timothy B. Rhyne and Steven M. Cron jointly received the Charles Goodyear Medal in recognition of the singular impact of the Tweel.[17]

Uptis

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Michelin partnered with GM in 2020 to offer the Unique Puncture-proof Tire System (Uptis) that may be available for the 2024 model vehicles. [18] The tire made its first public appearance at the Internationale Automobil-Ausstellung (IAA) mobility show in Germany on an electric Mini Cooper.[19]

GM began testing the tires on a fleet of 2019 Chevrolet Bolt electric cars with the possibility for the Uptis to be an option on some GM vehicles in 2024.[20]

The Uptis uses an aluminum wheel assembly and rubber reinforced with glass composite and vinyl ester resin, an improvement over designs such as the Tweel.[21]

See also

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References

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Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia
The Tweel is an innovative design developed by the French manufacturer , functioning as a single integrated unit that combines the and to eliminate the need for , inner tubes, or air pressure maintenance. 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. Conceived in the late 1990s by engineers Dr. Tim Rhyne and Steve Cron at the company's research center in , the Tweel—short for "tire wheel"—received patents between 1999 and 2003, with an early prototype unveiled in 2005. 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. 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. 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 and ; and utility vehicles like ATVs, UTVs, golf carts, and machinery. 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.

History

Invention and Early Development

The Tweel was invented in the late 1990s by 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 due to punctures or loss of air pressure. Initial prototype development occurred at Michelin's Americas Research and Development Corporation (MARC) in , where the team focused on proving the feasibility of a non-pneumatic design capable of supporting loads through flexible structural elements rather than . This work built on earlier explorations of concepts dating back to the late 1990s, but shifted toward a fully airless system to enhance durability and reduce maintenance needs. The Tweel made its public debut at the 2005 in , where demonstrated a 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. The unveiling generated significant interest in the technology's potential to revolutionize design. Early recognition followed swiftly, with naming the Tweel the top innovation in its Automotive Technology category for the 2005 "Best of What's New" awards. 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. For their contributions to non-pneumatic tire technology, Rhyne and Cron were jointly awarded the Charles Goodyear Medal by the Rubber Division of the in 2022. These accolades underscored the Tweel's breakthrough status and paved the way for its commercialization beginning in 2012.

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. 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. 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 for integration on ZTrak series equipment. This move broadened market reach into 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. From 2023 to 2025, 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. The line also extended to utility task vehicles (UTVs) with models like the 26x9.00N14, alongside wheel options for mowers, though models faced backorder issues starting in early 2025 due to high , with restocking anticipated by late fall 2025 as of September 2025 (though some delays to spring 2026 were reported and partial availability has resumed). These developments have driven growing market adoption, as evidenced by the broader sector's expansion at a of approximately 6% through 2025, with Tweel contributing to increased productivity in , , and recreational applications.

Design and Technology

Core Components

The Tweel, a portmanteau of "" and "," represents a single integrated assembly that combines these elements into one non-pneumatic unit, eliminating the need for a separate rim or system. This design achieves airless functionality through a structural that relies on mechanical deformation rather than , with flexible spokes providing load support and shock absorption akin to pneumatic cushioning. 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. 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. The Tweel's outer layer consists of a replaceable rubber tread band bonded to the shear beam, allowing for targeted replacement of the surface without discarding the entire assembly. In terms of , the spokes are engineered to flex radially to enhance ride comfort by distributing vertical impacts and circumferentially to facilitate transmission and handling stability, all within a fully enclosed, airless framework.

Materials and Manufacturing

The Tweel tire employs high-strength , specifically a structural poly-resin formulation, for its flexible spokes, which deliver the necessary elasticity and resistance to 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 characteristics akin to those in conventional pneumatic , ensuring reliable grip across various surfaces. 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). 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. Manufacturing begins with injection molding of the 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 , 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 offering up to 10 times greater spoke durability compared to earlier versions. From an environmental perspective, the Tweel design minimizes 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 spokes are recyclable, supporting Michelin's broader goals for sustainable material recovery in . These attributes, combined with lower weight and no inflation-related , position the Tweel as a more resource-efficient alternative.

Performance Characteristics

Advantages

The Tweel tire's puncture-proof design eliminates the risk of from impacts or , significantly reducing in commercial operations compared to conventional pneumatic tires. This airless structure, supported by flexible spokes, maintains performance integrity without the need for repairs or replacements due to punctures. 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. 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 performance in real-world conditions. As a maintenance-free option, the Tweel requires no air pressure monitoring, 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. Environmentally, the Tweel's longevity reduces the frequency of tire replacements, minimizing waste and resource consumption over its lifecycle. Additionally, its design can lower , leading to modest improvements in during use. 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.

Disadvantages

Despite its advantages, such as resistance to punctures, the Tweel 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 and assemblies, attributed to the intricate required for the integrated polyurethane spokes and hub. 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. 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 (around 30 lbs) plus rim assembly, potentially reducing and maneuverability in lightweight vehicles like small UTVs or mowers. Early prototypes of the Tweel, particularly those developed before 2013 for automotive use, suffered from excessive and caused by spoke at higher speeds, issues that were addressed in later redesigns. 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. 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. 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.

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. 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. In the lawn and turf maintenance sector, the X Tweel Turf has become a standard for zero-turn mowers, particularly through its integration with equipment starting in 2015, where it minimizes turf damage via a consistent and even . 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. For recreational and agricultural applications, all-terrain models like the 26x9.00N14 X Tweel UTV, launched in , equip utility terrain vehicles (UTVs) and all-terrain vehicles (ATVs) for off-road use in farming and leisure activities. These tires offer durability on rugged paths, supporting loads in low-speed operations without air pressure concerns. 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. This growth reflects increasing commercial reliance on Tweel technology in for low-speed, high-durability scenarios across and light industries. The Tweel technology has also undergone testing for potential use in specialized applications, informing its robust design for extreme conditions.

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. In and applications, the Tweel has supported development for dynamic stabilization and extreme environments. It was fitted to the , a four-wheeled concept vehicle unveiled in 2005 that combines self-balancing technology with ATV-like capabilities, demonstrating potential for versatile robotic mobility. Additionally, a Tweel-derived Lunar Wheel was tested on NASA's Scarab rover in late 2008, including field trials in simulating lunar , to evaluate performance for and Mars exploration rovers under low-gravity and abrasive conditions. 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 in , prototypes equipped with Tweel tires highlighted their puncture-resistant performance on rough prototypes, influencing further innovation in design. As of 2025, continues collaborative research on Tweel variants for off-road and testing in extreme conditions, building on prior prototypes to advance durability in rugged, non-commercial scenarios such as robotic platforms. In recognition of its innovative potential, the 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 solutions in specialized mobility.

Uptis

The Uptis, or Unique Puncture-proof Tire System, is an prototype developed by as an evolution of its Tweel technology specifically adapted for passenger vehicles. Unveiled in at the Movin'On Summit in collaboration with , 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 . 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 EV vehicles to assess real-world handling and efficiency. Unlike the heavier Tweel suited for equipment, the Uptis prioritizes lower overall weight and puncture resistance for urban electric vehicles and autonomous robotaxis, potentially reducing by eliminating flats and enabling longer . 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. The Uptis received the Tire Technology of the Year award at the Tire Technology International Awards for 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. continues road testing with partners like and La Poste, but the Uptis has not yet achieved 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.

Other Airless Tire Innovations

Corporation introduced the Air Free concept in 2017 as an technology utilizing a flexible spoke structure made from thermoplastic resin to support vehicle weight without inflation. 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. 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. In 2016, Goodyear unveiled the Eagle-360, a conceptual spherical designed for urban electric vehicles and autonomous cars, suspended via to enable omnidirectional movement. This prototype integrates biomimetic principles, with a tread pattern inspired by feet for enhanced grip on wet surfaces, and relies on electromagnetic fields similar to systems for wheel attachment, improving maneuverability in congested city environments. While not yet in production, the Eagle-360 represents an innovative shift toward spherical geometries that could reduce in low-speed urban applications. As of 2025, advancements in additive manufacturing have led to BigRep's development of 3D-printed s for electric motorcycles, featured in their NERA e-motorbike project. These tires use flexible 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. This approach allows for and on-demand customization, addressing limitations in traditional molding for niche vehicles. Major tire manufacturers, including Goodyear and , have pledged commercial entries for passenger vehicles by 2030, driven by commitments to sustainable mobility solutions. 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. Production costs remain elevated due to like composites and resins, hindering mass-market viability despite such as reduced material and recyclability. These innovations align with broader goals, as airless designs minimize resource use in and eliminate disposal issues from pneumatic . 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 or spokes. No direct licensing or transfers have been reported among these competitors, fostering independent evolution in the sector.

References

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