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WHAT IS CUSHCORE?

Cushcore is more than just flat protection. It improves the overall ride quality and performance of your bike. Think of it as suspension for your tires.

CushCore fits inside the tires.  It divides the inner volume of the tire in half, with air underneath the tread and the CushCore insert next to the rim. The tire still requires air and you can tune air pressure as you would with any tire. This design stabilizes and damps the tire sidewalls while allowing the tread area to retain the resilient feel of a pneumatic tire.

FOAM TECHNOLOGY

In foam manufacturing, it is challenging to combine low weight with high durability.

Most impact absorbing, low-density foams are sacrificial, meaning they are destroyed in a single impact.  That’s how EPS helmet foam works, and that’s why helmet manufacturers recommend you buy a new helmet after a single crash.

CushCore is made from a cutting edge material that does things no other foam can do. It has both low density AND superb impact resilience.  The material is also waterproof, compatible with tubeless tire sealant, and tuned for appropriate rebound feel. Its ability to withstand repeated impacts without damage is more typical of foams that weigh twice as much.

Each CushCore insert is born in a huge aluminum mold, a manufacturing process which allows us to create the unique, patent-pending shape.   The shape helps secure the tire to the rim, and extends well beyond the rim flange to protect against impacts from all angles.  CushCore’s special shape also creates the lateral force against the tire sidewalls that gives CushCore the cornering stability and calm ride feel it’s known for.

A look at the competition illustrates differences between the materials.  Flat Tire Defender is 50 grams heavier than CushCore, yet it fills a much smaller volume within the tire.  Huck Norris is made from an open cell foam, which absorbs tire sealant and has only a fraction of the energy absorption capacity of CushCore.

Manufacturing this foam is challenging and expensive compared to other methods, but having tested so many different materials while developing CushCore, we found no other material comes close to the ratio of weight to durability. High quality foam is worth the investment.

CUSHCORE AIR VALVES

CushCore tubeless air valves are specially designed to work with a CushCore insert.  The air passageway is T-shaped, rather than a simple through-hole, which prevents the insert from obstructing air flow through the valve.

The valve body is CNC machined from 6061 T-6 anodized aluminum, with a tapered rubber collar permanently bonded at the sealing interface.  The valve core can be removed to add tire sealant.  A locknut with o-ring seal and valve cap and valve core tool are included.