The development of sustainable tires with optimized performance requires a comprehensive understanding of filler reinforcement mechanisms in rubber. The morphology and the dispersion of fillers play a key role in strain amplification, which affects durability, rolling resistance and wear. This work presents a 3D microstructural simulation framework for modeling filler aggregates, explicitly capturing their structure and spatial arrangement. By establishing a direct link between aggregate morphology and local strain amplification, the study provides new insight into how colloidal properties of fillers influence energy dissipation and, ultimately, tire rolling resistance. These findings contribute to the design of next-generation sustainable tyres.

• The role of filler morphology in strain amplification and energy dissipation in rubber composites
• How 3D microstructural simulations can be used to model filler aggregates and predict macroscopic tire behavior
• The challenges of mesoscale modeling of filled rubber, including aggregate representation and computational limitations
• How filler morphology and dispersion influence strain amplification
• How simulation-driven approaches can guide sustainable tire design and formulation