When the tire fails, the mission doesn't.
Segmented polymer run flat inserts keep tactical vehicles moving up to 100 km after ballistic or terrain tire damage. Hand-tool installation. 15% lighter than comparable run flats. No special equipment required.
What are military run flat inserts?
Military run flat inserts are internal support rings mounted inside tactical vehicle tires. Under normal conditions, they sit between the rim and the tire cavity — out of the way. When a tire loses pressure from a ballistic strike, IED fragment, or terrain puncture, the vehicle's weight transfers to the insert. The insert supports the load, locks the tire bead to the rim, and lets the vehicle keep driving.
This isn't a consumer run-flat tire with reinforced sidewalls. Military run flat inserts are separate, heavy-duty components — typically polymer, composite, or solid rubber — that bolt onto the wheel inside the tire. They're designed for armored vehicles carrying thousands of pounds per corner, not passenger cars.
Three types of military run flat systems.
Not all run flat inserts are the same. The material and design determine how they're installed, how much they weigh, and whether they can be serviced in the field.
| Segmented Polymer | Solid Rubber | Beadlock Only | |
|---|---|---|---|
| Installation | ✓ Hand tools — three bolt-together segments | Requires hydraulic press or fitting machine | Bolts to rim — no run-flat mobility |
| Weight | ✓ ~15% lighter — polymer construction | Heaviest option — solid rubber mass | Lightest — but zero deflation support |
| Field Service | ✓ Segments swap forward-deployed | Must ship to equipped facility | Rim-level only |
| Ballistic Protection | ✓ Antiballistic polymer — armored vehicle rated | Proven — but degrades with heat/friction | None — bead retention only |
| Mobility After Deflation | ✓ Up to 100 km | 30–50 km typical | 0 km — tire comes off rim |
| Reusability | ✓ Unbolt, inspect, re-use | Often single-use after deflation run | Reusable |
Polymer run flat inserts: lighter, faster, field-ready.
Traditional solid rubber run flat inserts have been the standard for decades. They work — but they're heavy, they require a hydraulic press to install, and once they're in, field service is nearly impossible.
Segmented polymer run flat inserts change the equation. Three bolt-together segments replace a single 200-pound rubber donut. The weight savings — typically 15% per wheel — adds up across a fleet. More importantly, the segmented design means installation happens with hand tools at the motor pool, not at a depot with specialized equipment.
For forward-deployed units, this is the difference between a vehicle returning to duty in hours versus days.
- Antiballistic polymer — engineered for the armored vehicle market, not adapted from commercial materials.
- Segmented design — three pieces bolt together around the rim. No press. No machine. No special rig.
- Field-swappable — damage one segment? Swap it. Don't scrap the whole insert.
- Long-life lubricant — paired with purpose-built RunFlat grease (NSN 2640-01-419-6200) that cuts friction during run-flat operation.
Platform Compatibility
Polymer run flat inserts are configurable for a wide range of tactical wheel and tire combinations:
- HMMWV — 16.5" and 17" wheel applications
- JLTV — next-gen light tactical vehicle
- MRAP — heavy armored platforms
- FMTV / LMTV — medium tactical vehicles
- Stryker — 8×8 armored fighting vehicle
- HEMTT / PLS — heavy expanded mobility
Hand-tool installation. No press. No problem.
The segmented design eliminates the single biggest bottleneck in military run flat deployment: the hydraulic press. Three polymer segments feed through the tire bead, bolt together around the rim, and torque to spec — all with standard hand tools.
DLA supplier. CAGE 93ST9. SAM.gov registered.
The Toota Group is a registered defense supplier with active CAGE code 93ST9 and JCP Level 2 certification. We supply run flat inserts, run flat lubricant, complete wheel assemblies, and military-grade tires to government and defense fleets through DLA and direct contracting vehicles.
Run Flat Inserts
Static and dynamic polymer run flat systems. Segmented, antiballistic, hand-tool installable.
View RunFlats →Run Flat Insert Kits
HMMWV 2640-01-419-6202, MaxxPro/Cougar 2640-01-563-1421, M-ATV 2640-01-599-6284, JLTV 2640-01-676-2900. Second-source polymer kits.
See the vehicles →Run Flat Lubricant
NSN 2640-01-419-6200 (tube) and NSN 2640-01-457-5552 (drum). Long-life grease for run-flat operation.
View Lubricant →Wheel Assemblies
Complete mounted assemblies — run flat insert, tire, wheel, torqued, CARC-painted, palletized.
View Assemblies →Ready to spec run flat inserts for your fleet?
Tell us your platform, wheel size, and operational requirements. We'll quote your program.