This paper introduces a new concept of a smart and sustainable tire based on a removable tread band: ECOTIRE. Current tires, though crucial for road information and vehicle control, such as braking, traction, and turning, remain disconnected from Advanced Driver Assistance Systems (ADAS). Additionally, their production, use, and recycling pose significant environmental challenges, requiring sustainable materials and lifecycle improvements. The ECOTIRE concept makes it possible to separate the part of the tire subject to wear and apply new materials with reduced environmental impact. At the same time, the service life of the casing is extended, facilitating the introduction of sensors that improve vehicle safety. This study explores the purely mechanical connection between the casing and tread, demonstrating the feasibility of this innovative tire structure while eliminating the need for rubber matrix-based materials for a proper bond between the two components. Experimental tests using a rubber sample to simulate the tire–road contact patch validate the effectiveness of the mechanical link under varying normal loads. Grip test results, measuring longitudinal and lateral forces, show promising performance. This advancement in tire technology marks a first step toward sustainability, tire performance, and smart integration, ultimately reducing environmental impact.

This study presents the development and first manufacturing realization of the ECOTIRE concept, a modular and sustainable tire system featuring a removable tread mechanically interlocked with a reusable casing. The concept aims to reduce rubber waste and improve recyclability by eliminating adhesive bonding and enabling tread replacement. Building on previous experimental and numerical studies that validated the interlocking performance, this work focuses on producing a scaled prototype using a low-cost molding process, which can serve as the basis for accessible and sustainable manufacturing. VMQ silicone rubber was selected as an eco-friendly material due to its durability, thermal stability, and processing versatility. A custom two-part aluminum mold was designed to replicate the optimized interlocking geometry, enabling accurate casting, curing, and assembly. The resulting prototype achieved precise fit, dimensional uniformity, and easy disassembly, confirming the manufacturing feasibility of the ECOTIRE concept and demonstrating its potential to support circular economy strategies through reduced material waste and extended tire component lifetimes.