A 3D-printed airless bicycle tire developed by YouTuber Berm Peak uses a modular design assembled from printed segments rather than a single molded piece. Four tire sections are printed at a time on a consumer 3D printer before being connected with dovetail joints and screws to form a complete tire. Flexible TPU is used for the tread, while a stiffer TPU supports the internal structure, and eight printed mounting sections secure the assembly to the wheel rim.
The design evolved through multiple prototypes, replacing an initial rigid X-shaped internal structure with a lighter and more compliant suspension pattern that improved ride quality. Printed on a Bambu Lab H2D using dedicated support material, the tire was tested on rocky mountain bike trails where it demonstrated strong climbing traction and impact absorption. During more demanding riding, the rear tire experienced progressive structural failure while the front remained intact, highlighting the different loading conditions experienced by front and rear wheels during off-road use.
Image Credit: Berm Peak
What Makes This Trend Stand Out
- Modular Tire Manufacturing
- Segmented construction introduces localized replacement, customization, and distributed production models that could reduce dependency on centralized tire molding infrastructure.
- Consumer-grade Performance Prototyping
- Affordable 3D printers and advanced TPU materials are narrowing the gap between hobbyist experimentation and functional outdoor equipment development.
- Airless Mobility Components
- Puncture-free wheel systems create room for new durability-focused designs across bicycles, scooters, and lightweight electric vehicles.
Sectors Adopting This
- Cycling Equipment
- Modular airless tires point to differentiated aftermarket products built around maintenance reduction, terrain-specific tuning, and rider personalization.
- Additive Manufacturing
- Functional tire assemblies showcase how multi-material printing can expand beyond prototypes into mechanically demanding end-use components.
- Micromobility
- Durable non-pneumatic tire systems may reshape fleet economics by lowering flats, downtime, and servicing requirements for shared mobility operators.
