This extra phase of design evolution pushed the project timeline, but it was what it took to reach the best possible tyre for the BFGoodrich driver — a cost that’s always worth it. The tread pattern was thoughtfully redesigned, and the prototypes that were made from it met the noise specs they set. Other tests came back, the design passed, and the contract was completed.
Step 5: Build Build Build
“During the testing phase, we’re only working on a couple of sizes. So once you get to that final sign-off on the tyre design. When we know we can make the tyres and meet the specs, the design becomes fixed, and we start working on replicating that design for all the different sizes we want to offer consumers. Often, over 40 sizes need to be optimized. In this phase, the project gets a lot bigger. More people come on board to create designs, molds, and pre-production tyres for all remaining sizes.”
Those pre-production tyres (one step farther along than development tyres) are created in three waves. First, it’s 15 that get robustly tested, then 25 double-check the results from the first batch. Finally, a set of 50 tyres are made for final triple-checking and official sign-off. This layered, rigorous process confirms that the tyre’s design can replicate its test results with consistency, meeting the performance standards each time. With these waves of tests passed, the tyre is ready to move into production mode, and eventually, a full-fledged launch.