Swissstop Brake Disc 180 mm 6 Screws

Design and modeling

In early 2015, SwissStop's engineering team carried out a series of laboratory tests on bicycle brake disc rotors. They then created digital models of these rotors and simulated the same test environments using advanced software. Comparison of the data confirmed that the simulations were accurate and effective, giving engineers the confidence to develop a series of digital prototypes for thorough testing and evaluation.

Heat and structure simulations

Among the various design concepts, heat transfer was extensively studied thanks to engineering simulation software. Relationships between convection, radiation, surface area and weight were used to determine the optimal design to maximize heat dissipation and strength while minimizing weight. The structure of each design was tested under braking forces ranging from typical hand pressure to theoretical maximums. Critical pressure points in the structure were identified with the objective of maximizing the strength and rigidity of the rotor.

Airflow analysis

Computational fluid dynamics (CFD) simulations were performed to study the airflow over the rotor surface and through the cutouts. A variety of profiles were tested to determine the effects of asymmetrical holes and optimize the cooling effect of airflow over the surfaces.

Final design

The final design was confirmed and visualized through further thermal and structural simulations.
Aiming to balance light weight with reliable thermal management and structural performance, a two-piece design was chosen: a 7075-T6 aluminum alloy spider and a SUS410 stainless steel brake track.
Vibrations will be minimized by the geometry of the brake pad contact area.

Lab tests

Laboratory testing of the Catalyst disc rotor confirmed the results of engineering simulations.
The Catalyst excels in endurance tests: while standard brake systems gradually decline to eventual structural failure, the Catalyst provides consistent braking torque over time.
Additional testing demonstrated extremely efficient thermal management, especially at the shortest braking distances, very low wear rates and structural integrity under heavy braking, outperforming current industry leaders.
Practical testing of the prototypes allowed the development team to determine the optimal balance between two of the primary but competing characteristics: brake performance and weight.
A carefully calculated few extra grams of material were added to the outer ring in order to achieve shorter braking distances.
Additionally, engineers selectively added material to some specific sizes to further improve performance and durability.

Characteristics:

• Compatible with all organic and sintered pads. Optimized for SwissStop EXOTherm2.
• Weight: 156g
• Thickness 1.80mm