Sustainable Manufacturing of a Modular Tire with Removable Tread: Prototype Realization of the ECOTIRE System

This study presents the development and first manufacturing realization of the ECOTIRE concept, a modular and sustainable tire system featuring a removable tread mechanically interlocked with a reusable casing. The concept aims to reduce rubber waste and improve recyclability by eliminating adhesive bonding and enabling tread replacement. Building on previous experimental and numerical studies that validated the interlocking performance, this work focuses on producing a scaled prototype using a low-cost molding process, which can serve as the basis for accessible and sustainable manufacturing. VMQ silicone rubber was selected as an eco-friendly material due to its durability, thermal stability, and processing versatility. A custom two-part aluminum mold was designed to replicate the optimized interlocking geometry, enabling accurate casting, curing, and assembly. The resulting prototype achieved precise fit, dimensional uniformity, and easy disassembly, confirming the manufacturing feasibility of the ECOTIRE concept and demonstrating its potential to support circular economy strategies through reduced material waste and extended tire component lifetimes.