It starts with the carcass, the tire’s structural backbone. This is usually a woven fabric (nylon or polyester) defined by TPI (threads per inch). Higher TPI = thinner threads, more flexibility, lower rolling resistance. Lower TPI = thicker threads, more puncture resistance and durability. Engineers choose this based on riding discipline (XC vs enduro vs downhill). Next comes bead construction. The bead anchors the tire to the rim and is typically steel (wire bead) or aramid/Kevlar (folding bead). Modern tubeless tires use precisely shaped beads and rubber coatings to create an airtight seal under pressure—this is not trivial and requires micron-level consistency during manufacturing. Then comes rubber compounding, one of the most complex steps. Tire rubber isn’t “just rubber.” It’s a blend of natural rubber, synthetic elastomers, carbon black or silica fillers, oils, and curing agents. Many MTB tires use dual or triple compounds: harder rubber in the center for low rolling resistanc...