Disc Brake Caliper

This design/build project enabled a manufacturer of after-market specialty automotive hardware to expand their product offering and profitability.

Changes were made to standard product design that considered the machining and setup effort, which resulted in fewer setups and shorter machining cycle times without compromise to the device function.

Challenge

For a client in volume production of specialty automotive hardware, our challenge was to optimize the design of a disc brake caliper in order to minimize the number of machining steps without sacrifice to function.

Solution

•  created a 3-D ‘as-built’ CAD model of the existing hardware using SolidWorks software
•  reviewed the applicable SAE automotive design standards
•  changed the shape and features of the mating parts while maintaining good structural integrity and fluid flow performance
• output the model to a CAM station to prototype and ultimately mass-produce the parts on a Deckel Maho DMC 64V Linear milling center

Services/Skills

•  3-D CAD modeling
•  Mechanical Engineering
•  Mechanical Design
•  DFM (Design for Manufacture) principles

Results

While this project is still in progress, the machining optimized caliper halves will be made during open cycle time on a high-speed linear drive Deckel Maho vertical machining center. This combination of optimization and availability will enable the manufacturer to remain price competitive and yet achieve target profit margins.