A semi-pneumatic tire assembly including a tire casing (22) and a lining (26) is provided. The lining (26) includes a contoured inward surface (30) defining an inflation chamber (18) about an associated wheel rim. The lining (26) minimizes the risk of puncture damage from an object penetrating the tire casing (22) while allowing pneumatic cushioning of the ride and cooler running temperatures as compared to solid-fill tires. Additionally, the semi-pneumatic tire will carry the same load or more than the same tire filled with permafoam and/or solid urethane foam wingfil. The tire assembly is formed by injecting a curable, lining-forming material (96) into a cavity (57) defined between the tire casing (22) and a molding member (50). The molding member (50) includes a contoured outer surface (54) which molds the inward surface of the lining (26). The molding member (50) may be an inflatable airbag (100) retained in the tire assembly during service. Alternately, the molding member (50) may be a solid core (114) which is removed prior to mounting the tire casing (22) and lining (26) on the associated rim.
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