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Wheel reinvented for giant mining machines gains traction in marketplace

The Air Suspension Wheel has undergone testing in mining operations around the world. [Credit: Photo courtesy of Global Air Cylinder Wheels]

 

 

A Phoenix-based engineering innovator called Global Air Cylinder Wheels (GACW) is making real inroads in the mining industry with its Air Suspension Wheel (ASW) technology -- a giant steel wheel drum and hub system connected by cylinders and oil dampers. The mechanical technology is aimed at eliminating full-size rubber tires from mining big rigs, boasting a lifetime that equals that of the vehicle among its many benefits. The company says it already has over $6 million in anticipated purchase orders from six mining companies in the United States, Canada, and Australia.

Air Suspension Wheel design highlights. [Credit: Image courtesy of Global Air Cylinder Wheels]

 

 

The basic system design features an inner steel hub with an outer steel drum that are connected by 12 nitrogen-filled cylinders and six oil dampers, which provide the suspension -- floating the vehicle body on the mechanical setup. GACW says the ASW "is engineered to replicate the tire size, load-bearing capacity (or more if desired), and deflection of current rubber-tire systems" and that "ASW's overall weight is within the vehicle manufacturer's guidelines."

Air Suspension Wheel design. [Credit: Screenshot image courtesy of Global Air Cylinder Wheels]

 

 

The outer drum can be fitted with bolt-on, customized polyurethane (PU) or steel treads, which can be individually replaced without removing the wheel. The ASW system as a whole can be customized as well. PU treaded shoes have a hardness range from Duro A55 to D85. Fire-retardant treaded shoes are also available.

According to GACW, the nitrogen cylinders interconnecting the rim and drum have bidirectional movement and have a rated pressure of 2,500 PSI and a burst pressure of 10,000 PSI. The inner wheel and outer tire structures are made from high-performance ductile steel that has been welded and bolted together to withstand extreme conditions. "The solid, treaded shoes are designed to last three to five times longer than OTR tires. They do not overheat and there is little deformation," the company says.

For the future, GACW envisions downsized versions of its ASW that can be used on all types of vehicles that currently use a rubber wheel, including wheelchairs, bicycles, cars, buses, trucks, agricultural vehicles, and other off-road vehicles fitted with appropriate treads.

The ASW system in this demonstration wheel (left) features 12 nitrogen-filled cylinders; six on one side and six on the other side of the wheel assembly. The ASW on the right has been fitted with bolt-on polyurethane treaded shoes instead of steel ones. [Credit: Images courtesy of Global Air Cylinder Wheels]

 

 

 

 

GACW recently announced it has launched its third equity crowdfunding campaign on StartEngine with the aim of raising $3.2 million under Regulation CF. It is part of a broader, board-approved capital strategy to secure up to $15 million over the next 18 months to accelerate commercialization, fulfill purchase orders, and expand operations globally.

[Credit: Video by Global Air Cylinder Wheels]

The campaign follows a strong funding track record, including a successful May 2025 raise of approximately $1.47 million through Dealmaker, which funded the fabrication and delivery of ASWs for an ongoing trial with a major U.S.-based iron ore mining company. The trial is expected to conclude before the end of 2025 and represents a critical milestone as the company transitions from R&D to revenue generation.

The company's patent portfolio also continues to grow, with 75 issued patents and more than 120 pending applications internationally.

[Credit: Photo courtesy of Global Air Cylinder Wheels]

 

 

The steel mechanical wheel system with in-wheel pneumatic suspension boasts a host of benefits, including a more eco-friendly total lifecycle than rubber tires; stronger, safer, and better overall performance; and being a more cost-efficient option over the long haul -- the company says the wheel "is up to 60% more economical over the lifetime of the wheel." The wheel cannot explode or catch fire the way a giant rubber tire can, and its microplastics or rubber dust emissions are negligible compared to its full-size rubber-wheel counterpart. Steel is also easily recyclable -- something that is certainly not true of full-rubber tires.

GACW says the ASW wheels can be designed to handle higher payloads than traditional rubber tires and are designed to cope with more lateral side load, making them more stable. There are also possible fuel savings that could really add up, including from the smaller ground contact area of the wheel. Maintenance is an additional consideration, and the mechanical system should require less over its lifetime. "The cylinders need a yearly check, and the seals are designed to last three years," says the company. "The bolt-on polyurethane treaded shoes are individually mounted and are easily replaced during a fuel stop." Harmen Van Kamp, CEO and co-founder of Global Air Cylinder Wheels, was recently interviewed by Tire Review. You can view the whole session at https://www.youtube.com/watch?v=Mb9Ji8E3oj0&t=4s.

This is certainly not the first alternative tire system we've seen, but it looks like it might have a pretty good chance of succeeding -- in mining, at least. Timing can be a big factor, and the more money this design can save, the better chance it will have to survive in the mining world. The ASW has undergone multiple rounds of field testing at mining sites of different mining companies in the United States, South Africa, and Chile. The company says the results have been "progressively positive." The testing has also brought the ASW to Technology Readiness Level (TRL) 7, a NASA-developed measurement of technology maturity. TRL 9 is a commercially ready product.

Source: Global Air Cylinder Wheels

Published October 2025

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