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Described is the process of designing and manufacturing tubeless wheels for the Mars rover with structural infill by the AGH Space Systems scientific club, who will take part in the University Rover Challenge competition. Some of Mars rover subsystems’ are so unique hence they should be manufactured from the beginning. The algorithm for generating the structural infill has been proposed. The strength tests were conducted for the preliminary identification of material parameters, and their results were used in FEM strength analysis. Wheels have been made of polymers with fused filament fabrication (FFF) additive technology, and then applied in the KALMAN rover.