Multiscale surface and friction characterization of an ECOTIRE modular tire interface: From manufacturing to measurement

• A novel modular tire concept (ECOTIRE) is introduced, featuring a removable, eco-compatible tread band. • Surface and friction behavior of rubber and silicone materials are analyzed using full-scale, operational test rigs. • Static friction coefficients and surface roughness (Ra, Rsm) were experimentally measured for multiple elastomeric material pairs. • Results show strong compatibility between EPDM65 and Silicone for mechanical interlocking without adhesives. • The multiscale measurement approach links microscopic surface data with macroscopic grip performance under various normal loads. ECOTIRE is a novel concept in sustainable tire design, featuring a modular architecture with a removable tread band that separates the wear-prone component from the casing. This innovation facilitates the use of eco-friendly materials, extends casing lifespan, and enables integration of smart sensors to enhance vehicle safety. This study evaluates the mechanical performance of various rubber-based and silicone materials for their suitability in the casing and tread layers. More than ten candidates were pre-screened, and four were selected for in-depth tensile testing under varying loads using a custom-built test rig simulating tire-road contact. Results revealed that EPDM65 and silicone exhibited compatible mechanical behavior, and their hybrid combination delivered consistent grip and bonding performance across a wide range of normal loads. Comprehensive surface characterization, including roughness and friction measurements, supported these findings by confirming good interfacial contact and high static friction in the hybrid configuration. A pyramid-based interlocking geometry was developed to connect casing and tread without adhesives, ensuring force transmission and ease of replacement. The hybrid EPDM65–silicone interface showed strong mechanical bonding and performed reliably in both longitudinal and lateral loading conditions. Full-scale manufacturing and testing confirmed the practical viability of the concept. This multiscale, experimentally grounded study validates ECOTIRE’s potential as a smart, sustainable tire solution, combining material efficiency, mechanical reliability, and environmental responsibility.