Bosch is closing the gap between standard cast iron and premium ceramic brake disc rotors, offering improved performance at an affordable price. iDisc brake disc rotors feature a non-corrosive tungsten carbide coating, which packs a high-gloss appearance while reducing brake dust and wear.
A practical challenge
Slowing or stopping a vehicle entails a few fundamental problems. It generates brake dust, wears down the brakes, degrades brake effectiveness and impacts our air. Nearly a third of particulate matter emissions in road traffic comes from brakes and tires – half of that is brake dust. Bosch is tackling these challenges with the iDisc brake disc rotor and improving air quality as a result.
– portion of particulate matter emissions in road traffic from brakes and tires
Development takes shape
We began working on key technology elements that could work on an industrial scale in 2009. A three-year research and development effort produced materials and process technologies for iDisc. The process chain we developed enables us to manufacture a carbide-coated brake disc that meets the technical requirements for use in automobiles.
Several focal points were critical to the project’s success. We needed a new system of materials for the friction layer of the disc, so that performance and robustness could be improved. A new machining concept and laser procedure were needed to help form the surface of the brake disc and apply an anti-abrasion layer to it. Importantly, new quality assurance methods were created to ensure the highest standards of quality and safety.
Advantages of iDisc
The core of iDisc’s performance comes from its hard metal tungsten carbide coating. It not only reduces brake dust but also increases safety – especially in multiple consecutive braking maneuvers. iDisc performs similarly to more expensive ceramic brake discs during such maneuvers and maintains its deceleration power.
iDisc lasts longer than conventional disc brakes – up to twice as long, depending on the thickness of the coating. It also doesn’t corrode, which is especially important for electric vehicles, where flash rust can form on conventional disc brakes, impairing braking responsiveness. Electric vehicles with iDisc avoid this issue altogether. The iDisc is priced between conventional gray cast iron and high-end ceramic brake discs.
winner of 2017 Robert Bosch Innovation Award
The iDisc’s game-changing design and impressive development led to its recognition with the Robert Bosch Innovation Award in 2017. Volume production of the iDisc began the same year in Porsche Cayenne vehicles. In the future, we aim to expand this technology to the mid-range vehicle segment and make roads safer and cleaner for everyone
The iDisc brake rotor from Bosch is reducing brake dust emissions and delivering premium performance at an affordable price. Its non-corrosive tungsten carbide coating helped it win the 2017 Robert Bosch Innovation Award.