Pirelli Advances Tire Development with AI and 5G Connectivity
Last year, Pirelli introduced the first 5G-connected Cyber Tyre. This year, the company deepens its integration of connectivity and artificial intelligence (AI) in tire development. Leveraging AI algorithms, Pirelli has accelerated the creation of its new-generation P Zero tires, making connectivity a core component of its innovation strategy.
The P Zero Product Line
The P Zero range includes five variants: P Zero Trofeo Track, P Zero Trofeo RS, P Zero R, P Zero, and P Zero E. These options feature distinct treads, compounds, and sizes tailored for different vehicle categories—from high-performance sports cars to daily driver SUVs. Notably, the Track version is exclusive to the U.S. market.
Digital Transformation Accelerated by the Pandemic
The COVID-19 pandemic prompted Pirelli, based in northern Italy, to rethink how it designs, engineers, and tests tires. Like many companies, Pirelli sped up its digital research and development processes. According to Pierangelo Misani, Pirelli’s chief technical officer and executive vice president, this shift began years ago and now sees most tire development starting in digital simulators before moving to physical prototypes.
This approach relies heavily on creating a digital twin of each tire model. Digitization offers several benefits, particularly in reducing development time. Misani states that Pirelli has cut development cycles by at least 30%, delivering a fully digital product line in under 18 months—from concept to market launch.
Closing the Loop with 5G and AI
Thanks to 5G technology, Pirelli’s development cycle is now circular rather than linear. The process iterates between virtual compound simulations, lab predictions, design adjustments, and tire-and-driving simulators before the product hits the market. After launch, data from the Cyber Tyre’s sensors feed back into the system to inform the next development cycle.
Environmental and Efficiency Gains with AI
Traditional physical tire development consumes significant materials and manufacturing resources. By shifting much of this work into digital modeling, Pirelli reduces material waste and environmental impact. The AI-driven process resembles methods used in pharmaceutical development, where chemical compounds are modeled digitally rather than physically tested at every stage.
The company’s proprietary AI system, called the virtual compounder, has digitally modeled over 1,000 compounds for the P Zero line. This technology enhances accuracy by avoiding human error and the constraints of physical testing. The result is a tire lineup that supports higher torque, horsepower, and weight, while also being more sustainable and customizable to different automakers' needs.
Data-Driven Insights from Cyber Tyre Sensors
The 5G-connected Cyber Tyre transmits three key data points to Pirelli’s headquarters: tire vertical travel, direction of travel, and rotational forces. This sensor data is combined with GPS, weather conditions, vehicle type, and road information using AI to build a comprehensive understanding of tire performance and wear.
Such insights enable Pirelli to fine-tune tread designs and compounds, improving durability and safety. Additionally, AI helps identify usage patterns and optimizes the supply chain by predicting regional tire demand more accurately.
Expanding AI Expertise
To support this shift toward digital and AI-driven development, Pirelli is adjusting its workforce. By the end of 2025, the company plans to have 80 employees focused on AI and digital solutions, centralized at its facility in Bari, Italy.
For professionals interested in AI applications in product development, exploring training in AI modeling and digital simulation can be valuable. Resources such as Complete AI Training offer courses that cover these topics in depth.
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