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SwissStop Catalyst disc rotors deliver consistent brake torque over long durations where others experience gradual decline and brake fade. Due to extremely efficient thermal management, Catalyst provides notably shorter stopping distances with very low wear rates under hard braking, exceeding the current industry leaders.
In early 2015, the SwissStop engineering team conducted a series of laboratory tests on bicycle brake disc rotors. Next, they created digital models of these rotors and simulated the same test environments using advanced software. A comparison of the data verified that the simulations were accurate and effective, giving the engineers confidence to proceed with creating an array of digital prototypes to thoroughly test and evaluate.
Heat transfer within the design concepts was studied extensively using engineering simulation software. The 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 evaluated under braking forces ranging from typical hand pressure up to theoretical maximums. Critical pressure points in the structure were identified in order to maximize the strength and stiffness of the rotor.
Computational fluid dynamics (CFD) simulations were peformed to study airflow over the surface of the rotor and through the cut-outs. A variety of profiles were tested to determine the effects of asymetrical holes and optimize the cooling effect of airflow over the surfaces.
Thermodynamic simulations, structural analysis and fluid dynamic visualizations were conducted in collaboration with the Institute for Energy Technology at HSR University of Applied Science.
The final design was confirmed and visualized with further thermal and structural simulations.
A two piece design consisting of a 7075-T6 aluminum alloy spider and SUS410 stainless steel brake track was chosen to balance light weight with reliable thermal management and structural performance.
Vibrations are minimized by the geometry of the brake pad contact area.
Ø 140mm 1.85mm 110 g
Ø 160mm 1.80mm 128 g
Ø 180mm 1.80mm 156 g
Ø 203mm 1.85mm 198 g
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