Global Air Cylinder Wheels reports strong performance in extreme mining trial

After years of engineering development and large-scale field testing, Global Air Cylinder Wheels® (GACW), the Phoenix-based innovator behind the patented air suspension wheel (ASW), has reached a key milestone in its transition from research and development to commercial deployment for 2026, following successful extreme-condition validation trials in Minnesota mining operations.

The recent winter trial subjected the company’s non-pneumatic mechanical wheel system to real-world operating conditions in Minnesota in December, with temperatures ranging from approximately -20°F to -40°F under full production loads and operational conditions. The testing focused on validating suspension performance, tread compounds, lubrication systems, and traction in extreme sub-zero mining conditions.

“We’ve already proved our wheel works in the real world”, said Harmen van Kamp, CEO of Global Air Cylinder Wheels. “The wheel is real. Now we’re focused on making it better and preparing it for commercial release.”

The company recently launched its sixth Regulation CF equity crowdfunding campaign on StartEngine. So far, the campaign has raised over US$539 000 of its US$1.4 million goal, in addition to previously raising over US$9.4 million, and is scheduled to run through 9 April 2026.

The Minnesota programme evaluated multiple polyurethane tread compounds with varying hardness levels. According to company leadership, all three configurations performed well in the extreme cold, showing no observable degradation or failure in suspension cylinders, O-rings, bearings, or lateral restraint systems during testing.

Cold-start performance and lubrication systems were closely monitored throughout the trial. Traction was evaluated on significant grade ramps under full payload conditions.

In addition to extreme cold performance, prior testing in wet and muddy conditions demonstrated the mechanical wheel’s point-load design can penetrate surface mud and clay layers to reach firmer ground, improving traction while avoiding the rock-cutting vulnerability and flat tyre risk associated with rubber tyres.

Unlike traditional off-the-road (OTR) tyres, which are multi-tonne, pressurised rubber bladders, GACW’s ASW is a primarily steel-based, non-pneumatic wheel integrating nitrogen-filled suspension cylinders and dampers. The design eliminates stored energy risk associated with high-pressure tyre failures and reduces exposure during maintenance procedures. Mining tyre changeouts can involve components weighing more than 10 000 lb and exceeding 13 ft in diameter, often requiring extended downtime. In large-scale operations, downtime can translate into significant daily production losses, placing safety and uptime at the centre of operational decision-making.

“Our focus has always been solving one of mining’s most dangerous and logistically complex maintenance challenges”, Van Kamp said. “Field validation under full production conditions gives operators confidence that this technology can perform where it matters most.”

The trial also marked validation of the company’s 13th-generation suspension cylinder design. According to GACW leadership, the core suspension system no longer requires functional redesign, with current efforts focused on manufacturing maturity and production readiness.

To support its transition to full commercial operations, GACW has expanded its operational infrastructure, including the appointment of a dedicated quality manager and the implementation of ISO-aligned quality management systems. The company has completed its preliminary audit and is progressing through the final stages of accreditation, with full ISO certification anticipated by May 2026. These processes are designed to ensure supply chain traceability, manufacturing repeatability, and global service readiness as commercial production scales.

PO negotiations with select global mining operators are already underway, with the company entering advanced discussions for its initial commercial deployments. According to company leadership, the first phase is expected to involve approximately eight truck configurations, representing potential revenue of approximately US$8 million based on initial deployment scope, with manufacturing targeted to commence mid-2026 following final purchase order execution.

Mining operators typically deploy new technologies in phased rollouts, beginning with one or two trucks before broader fleet integration. GACW expects these initial deployments to be followed by expanded adoption across additional sites as performance data is gathered and internal approvals are completed. The company’s initial geographic focus includes the US, Canada, Australia, and select South American markets.

As part of its commercialisation strategy, GACW is introducing a ‘Wheels as a Service’ model that allows mining operators to adopt the ASW under an operating expenditure structure rather than capital expenditure, reducing adoption friction while supporting lifecycle service continuity.

The ASW is designed to last the lifespan of a haul truck, estimated at 10 – 15 years, with replaceable tread segments and rebuildable components engineered to reduce waste and improve long-term cost predictability.

GACW’s intellectual property portfolio includes over 75 issued patents and more than 120 pending applications globally, reflecting years of development across suspension, damping, tread, and mechanical wheel architecture. Overall, the company has reported conducting 76 wheel configurations across 13 asset groups, supported by more than US$10 million invested in research and development to reach operational readiness.

Although mining represents the first large-scale commercial focus, GACW’s ASW was conceived as a scalable mechanical platform. The company’s patent portfolio supports potential future adaptation across heavy construction equipment, armoured and specialty vehicles, commercial transport applications, and smaller mobility formats, such as wheelchairs and bicycles. By first validating performance in one of the world’s most demanding industrial environments, the company believes it can establish a foundation for broader licensing and cross-industry deployment over time.

GACW is preparing for a planned Regulation A+ offering targeted for 2Q26, subject to SEC qualification, to support commercial expansion.

“We’ve completed the testing validation phase”, Van Kamp said. “Now it’s about disciplined execution, manufacturing maturity, and delivering a safer alternative to traditional mining tyres.”

Read the article online at: https://www.globalminingreview.com/mining/09032026/global-air-cylinder-wheels-reports-strong-performance-in-extreme-mining-trial/