BRAKE-THRU - A Lightweight Automotive Brake Rotor For the Emerging LCV Market

BRAKE-THRU is a new type of automotive braking system for future Low Carbon Vehicle’s. The aim is to provide this emerging industry with a lightweight and cost-effective alternative to grey cast iron rotors - the traditional material of choice for over 50 years. In future LCV’s, weight will be critical, where currently, car makers still have to fit cast iron rotors to their vehicles as no economically viable lightweight alternative exists. The weight burden does not merely extend to the rotors themselves [40kg for family saloon], it also forms part of the vehicle un-sprung weight. Unsprung weight reduction is highly beneficial for improving fuel economy and a key enabler that then allows the onward safe reduction of the sprung weight in modern vehicles, where any reduction has a positive effect on acceleration and cornering and also improves the ability of the suspension in maintaining tyre grip. The fuel savings from unsprung weight reduction are far more substantial than achieved by equivalent reductions to the car body. BRAKE-THRU is a 6 partner 2yr initiative, bringing together knowhow from the world of automotive friction materials, car brake system design, and the composites industry.