The production of carbon ceramic brake discs represents the technological forefront in the field of braking systems. Thanks to an optimized industrial process, BSCCB is able to ensure a finished product with excellent chemical, physical, and mechanical characteristics, suitable both for road use in variable climatic conditions and for the most extreme applications on the track. 

The entire product lifecycle* common to all the different types of discs (CCM, CCB, and Dyatom) is divided into precise and rigorous phases: from the mixing of raw materials to the final assembly and the most stringent quality controls.

Dosage and Molding

The process begins with the precise dosing and mixing of the essential raw materials: short carbon fibres (chop fibres) and phenolic resin. The short fibres are randomly distributed within the mixture in well-defined sizes and quantities. The compound is then introduced into special moulds to achieve the geometry of the brake disc ring defined during the design phase. During this forming stage, internal ventilation channels for self-ventilation are also created: an approach that preserves the uniformity of the material's structure, avoiding subsequent invasive mechanical processing.

Brake disc ring drilling

Subsequently, the brake disc ring is drilled to create ventilation holes, which serve both to cool the disc under extreme usage conditions and to refresh the brake pad, ensuring the friction coefficient defined during the design phase is consistently maintained.

Pyrolysis (carbonization)

The printed semi-finished product undergoes a high-temperature heat treatment called pyrolysis. During this process, the organic substances present in the phenolic resin are carbonized. The result is the transformation of the component into a Carbon/Carbon material (carbon in a carbon matrix), characterized by a shape and porosity (density) perfectly calibrated for the subsequent treatment.

LSI process (Liquid Silicon Infiltration)

The next phase is the infiltration of liquid silicon, known as the LSI process (Liquid Silicon Infiltration). The molten silicon penetrates capillarily into the carbon matrix and, chemically combining with it, generates silicon carbide (ceramic) through a reaction. It is precisely this chemical transformation that gives the carboceramic disc its exceptional hardness and the abrasion resistance of the pad, ensuring a service life virtually equal to the vehicle's lifespan.

The AoX treatment

The AoX treatment in carbon-ceramic brake discs is an anti-oxidation treatment designed to protect the carbon component at high temperatures. Through pore sealing and protective coatings, it reduces oxygen penetration and limits material degradation. This helps preserve structural integrity, mass, and performance over time, increasing the disc's lifespan and ensuring greater stability even under extreme usage conditions, such as sporty driving or on the track.

Mechanical finishing

Once the ceramic structure is completed, the raw disc exhibits a hardness that allows it to be processed only with specific tools. Precision grinding and finishing of the friction surfaces are then carried out using industrial diamond machinery and tools.

Design and assembly of bell

To enable the attachment of the brake disc ring to the wheel hub, it must be paired with a metal bell. Since the ceramic brake disc ring and the metal bell have very different thermal expansion coefficients, the joining system is crucial.
•    Tooth geometry: The teeth and coupling grooves are shaped to ensure perfect relative radial sliding between the surfaces, avoiding stress or forcing.
•    Elastic compensation elements: To address minor geometric irregularities and distribute loads evenly during braking action, special metallic elements with elastic deformation are interposed between the contact surfaces of the bell and the CCM brake disc ring.

Quality control and validation

Safety and reliability are the pillars of our production. For this reason, 100% of the units produced undergo strict internal verification protocols. The inspections, which are completely non-destructive, include:

  • 100% measurement of the disc dimensions and the surface effects of the brake disc ring, to ensure proper pairing with the brake pad in terms of functionality, such as performance and NVH.
  • 100% inspection of density and weight after the most critical thermal processes, to ensure the correct chemical composition of the components that make up the carbon-ceramic disc.

Only the discs that successfully pass every validation test and reflect the rigorous qualitative reference values are approved for the market, ensuring consistent performance, absence of thermal deformations, and maximum braking efficiency.

(*) For CCB and Dayatom discs, the production process includes an additional phase between the pyrolysis and silicification stages. In this phase, the CCB and Dyatom discs undergo the friction layer application, which involves applying a functional surface layer designed to optimize the interaction between the disc and the pad. This layer, typically made of specially formulated ceramic materials and silicon carbide, enhances the coefficient of friction, modulability, and wear resistance. This phase is preceded and followed by mechanical processing and is followed by an additional pyrolysis phase to carbonize the phenolic resin used during the application of the layer itself. Furthermore, exclusively for the DYATOM disc, during the molding phase, in addition to the short carbon fibers that form the disc fins, two rings of long carbon fiber (felt) are inserted to form, in a true co-molding phase, the disc plates themselves. This material is characterized by extreme mechanical and thermal properties, giving the DYATOM disc performance levels above those of discs made entirely of short carbon fiber (CCM and CCB).

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