Lightweight Two-Piece Discs

Background

On several vehicles, Mercedes Benz introduced a composite brake disc, this a two piece rotor with a pot made of sheet steel, with a wall thickness of 2.5mm, and a friction ring made of cast iron. The two components are connected by a special construction (splines) by an interference fit. The tooth profile of the brake disc pot engages with a complementary tooth profile in the friction ring to transmit the torque. This development set a new track width for their cars and meant that if somebody installed a standard disc into such cars, the width increases and the driving allowance of the car is no longer valid. In 2019 Jaguar Land Rover and Tesla followed, using the same concept for their vehicles.

Benefits

Mercedes introduced these lightweight, two-piece discs due to the benefits they provide:

Reduction of fuel consumption which leads to verifiable CO2 savings
Improved thermal conductivity which reduces thermal distortion, minimises disc coning and causes a reduction in cracking behaviour
The connection concept further improves the thermal conductivity of the brake disc which leads to a reduction of thermal distortion leading to less brake scratching
Reduction in noise or vibration due to the decoupling of the friction ring and disc
Improvement of driving characteristics by reducing the non-springy masses of the brake system
Weight reduction

Vehicle Use

At the moment the following manufacturers are using the lightweight two-piece rotors with a steel pot disc:

Mercedes Benz, Vehicle types C-, E- and S- class, introduction 2016
Mercedes Benz, Electric vehicles EQC, EQE, EQS
Jaguar Land Rover, Models: PACE, XE, XF, Discovery, Range Rover, Evoque, Introduction 2019
Tesla, Model Y, Introduction 2019

Issue

Usually these rotors are only available directly over authorised Mercedes-Benz, Jaguar Land Rover and Tesla aftermarket dealers. Additionally, only licensed suppliers (e.g. Brembo S.p.A in Italy) are allowed to manufacture those composite brake rotors and they are not allowed, due to certain defined restrictions, to sell those to any other customer into the aftermarket.

Over the years, many suppliers have tried to create a copy to enable themselves to sell parts into the aftermarket. To date, there are only two solutions which fulfil technical specification.:

1. Brembo Co Cast Design

This casts the steel pot (sheet thickness 2.5mm) into the friction ring.

2. EURAG riveted solution

EURAG developed their own design which was similar to the BMW design.

The designs mentioned above are very scarce in the market right now and are often being sold at very high prices, this can be very problematic to aftermarket dealers who would need a large volume of these products at ideally lower prices.

That is where we come in!

Solution

Our Design

We are the exclusive supplier of a new comparable solution which is patented by our supplier and enables us to provide similar composite brake rotors (manufactured in Europe) for Mercedes Benz, Jaguar Land Rover and Tesla vehicles. Importantly each product is a two piece rotor and has passed all European standards and is certified by an ECE R90 approval which means they are compliant and legal for use in the UK and enables them to be used as replacements in the vehicles mentioned.

Our development is based on the Pin Drive design (AMG, Porsche, BMW, Audi, etc.), which has been in the vehicle industry for many years. The steel pot is pressed into the pre-turned friction ring and then connected radially with pins at the inner diameter. The design pin connection is patented by our supplier. The pins are placed in the middle of the ring to obtain further technical advantages (reduced tendency to crack, coning, etc.). In contrast to the known methods, it is a simple joining process with subsequent pinning.

For the C and E class, as well as for the electric vehicles from Mercedes Benz, a uniform pot size is used, primarily for the reason to reduce the variants. The brake disc sizes of the S class are also covered with one pot size. Finally the same corrosion protection coating as the original parts is applied to the disc.

Price

Our prices are highly competitive and are dependent on the specific disc required and the volume needed. Please get in contact using the form below to find out more!

Availability

We have a high availability of these right now! Please get in contact using the form below to find out more!

Technical advantages

Apart from price advantage, our two-piece solution hosts greater technical benefits when compared to Mercedes Benz discs (when tested using Mercedes Benz standard testing):

Same performance behaviour (100%)
Same wear behaviour (100%)
Same fatigue behaviour (100%)
40% improvement in crack resistance (140%)
20% improvement in corrosion behaviour (120%)
40% improvement in comfort behaviour (140%)
10% reduction in weight (90%)

What We Offer

Currently we are able to offer lightweight two-piece rotors for the following Mercedes Benz vehicles:

We are currently finalising the production and testing of the discs for the following Jaguar Land Rover & Tesla Vehicles which we also aim to be able to offer very soon!

To make an order or find our more please contact us directly!

Flat 11, 84 Elm Grove

Portsmouth

PO5 1LN

E-Mail: DAEnterprises1702@gmail.com