Researchers at Universidad Carlos III de Madrid have developed ECOTIRE, a modular tyre fitted with sensors that could reduce waste and improve road safety. The prototype replaces only the tread as it wears, while keeping the rest of the tyre in use.
The ECOTIRE project replaces the usual chemical bonds that hold tyres together with a mechanical system. Only the tread, the part that wears down, is replaced, and it accounts for less than a fifth of the tyre’s weight. The rest can stay in use much longer. Universidad Carlos III de Madrid says the design could reduce material use and tyre waste in the auto industry.
Lead researcher Daniel García-Pozuelo points to a major problem: old tyres pile up as waste and shed harmful particles into the air. The team’s mechanical connection and silicone rubber have shown promising results. Tests found one-tenth the wear of standard rubber, along with steadier performance. The findings, published in Applied Sciences, point to a tyre that could last longer and pollute less.
The ECOTIRE also has sensors that turn the tyre into a real-time data source. They track pavement forces, contact pressure, slip angle and grip. This information could help Advanced Driver Assistance Systems (ADAS) and self-driving cars respond faster to road risks. In independent tests published in Measurement, researchers placed the modular tyre on a rotating drum and controlled load, radius, slip angle, slip ratio and pressure to assess its performance under different conditions.
García-Pozuelo says the goal is a tyre that lasts longer and communicates with the car and the road. In practice, it could alert systems such as ABS to aquaplaning or ice before the driver notices, potentially enabling earlier, safer braking. Universidad Carlos III de Madrid says data on sensor accuracy, grip on wet or icy roads, and regulatory approval is still missing. The features remain unproven in real-world use.
Laboratory results published in Measurement show that the modular tyre withstands different loads and pressures, with performance close to that of regular tyres. It is not yet ready for mass production. García-Pozuelo believes it is getting close, and industry partners could help bring it to market.
Carmakers face pressure to reduce their environmental impact as interest grows in smarter, greener tyres. ECOTIRE’s modular design and real-time sensing align with wider mobility trends. Spain is already moving toward self-driving vehicles, as reported earlier by this publication.
ECOTIRE remains a prototype. The next step is to move from laboratory results to everyday use, testing both the technology and the willingness of carmakers and regulators to set a new standard for tyres.
