OTR Engineered Solutions has introduced OTR3DLab, a physical prototyping service that uses large-format 3D printing to produce full-scale concepts for off-the-road tires, wheels, tracks, and related components.

The Rome, Georgia-based company said the service can produce physical prototypes in a matter of weeks, compared with the months traditionally required for tooling and prototype development. The goal is to allow customers to evaluate a design’s appearance, fitment, proportions, clearance, and overall direction before investing in production tooling.

“OTR3DLab gives customers something they have never truly had before in the off-the-road market: the ability to physically experience a full-scale concept before making major tooling decisions,” said Patrick Sexton, global VP of engineering and innovation at OTR Engineered Solutions. “Instead of relying only on drawings, renderings, or small-scale models, customers can now see the product, touch it, and review it on actual equipment. It allows them to make quicker decisions with reduced risk.”

The 3D printing system supports more than 1,000 materials, including flexible, rubber-like elastomers designed to replicate the appearance and feel of production tires. It can produce components up to 1 cubic meter, or about 35 cubic feet, allowing for full-scale prototypes of tire treads, tracks, wheels, castings, housings, and other components.

OTR said printed tire prototypes can be mounted to standard steel or aluminum wheels using conventional tire mounting equipment. This allows customers to evaluate tire-and-wheel assemblies on equipment for visual reviews and packaging studies before finalizing a production design.

Designing for the application

The need for faster prototyping also comes as tire manufacturers increasingly tailor tread designs and construction to specific vehicle applications and operating conditions. With factors such as tread design, compounds, and casing construction influencing wear, fuel efficiency, traction, and retreadability, the ability to create full-scale physical prototypes gives customers another way to evaluate application-specific designs before committing.