Method of Forming Road Surface Replicas Using 3D Printing Technology

Rolling resistance is a critical factor that influences vehicle energy consumption, emissions, and overall performance. It directly impacts fuel efficiency, tire longevity, and driving dynamics. Traditional rolling resistance tests are conducted on smooth steel drums, which fail to replicate real-world road surface textures, potentially skewing results. This article presents the process of designing surface replicas using 3D printing technology, which consisted of selecting the internal structure, material, and print parameters of the surface sample. In order to verify the designed structures, an original mechanical strength test was performed. The test was based on pressing the tire onto the test sample with an appropriate force that corresponded to typical conditions during rolling resistance measurements. The test results included surface texture profiles before and after the application of load, which were then superimposed to detect any possible sample deformation. The obtained strength test results confirmed the validity of using 3D printing technology in the process of obtaining road surface replicas.