Design and evaluation of Kresling origami-inspired non-pneumatic tires fabricated via FDM 3D printing

Abstract This study presents the design, fabrication, and evaluation of Kresling origami-inspired non-pneumatic tires (NPTs) manufactured via fused deposition modeling using thermoplastic polyurethane. The research focuses on understanding how key geometric parameters—twist angle, layering strategy, and fold direction—govern the structural and dynamic performance of Kresling-based tire architectures. Nine design variants were systematically developed and experimentally tested under controlled impact conditions to assess load-bearing capacity, shock attenuation, and vibrational damping. Finite element simulations were first conducted to identify configurations with superior stress distribution and axial stiffness, followed by experimental validation using peak acceleration, root mean square acceleration, and frequency-domain analysis. Results show that a twist angle of 30°, particularly in two-layer configurations with alternating folds, consistently delivers the best balance between stiffness and damping. Layering was found to improve vibrational stability, while fold direction influenced strain distribution and symmetry under loading. The findings highlight the potential of origami-inspired geometries as tunable, manufacturable alternatives to conventional lattice structures in NPTs and offer a geometric design framework for future adaptive and high-performance tire systems.