Can carbon rotors provide better braking?

By Josh Patterson in Fort Collins, Colorado | Wednesday, Nov 21, 2012 9.07pm

Carbon fiber disc brake rotors are nothing new. Rotors constructed from a combination of carbon and ceramic materials have been used by the automotive and aerospace industries for decades, but the trickle-down to disc-equipped bicycles has been slow and plagued with numerous problems. Two design engineers think they have developed a product that solves these pitfalls while providing substantially better braking performance than anything currently on the market.

Aaron Stephens and Josh Gore are freelance design consultants who have worked on myriad projects ranging from injection molding to packaging solutions to high-pressure regulation. Both are avid cyclists but were outsiders to the cycling industry. The pair tinkered with improving numerous parts on their own bikes—improving dropper seat posts and building better ­lights for night riding—but it was a serious mountain bike crash three years ago that spurred the creation of Kettle Cycles and lead to the development of their first product: carbon disc rotors.

During a long descent, Stephens’ brakes overheated and failed.

“I was flat out enraged that I spent serious money on these brakes that performed very poorly,” said Stephens. “You’d think that, with the amount of money involved, most of these products would be pretty solid, but they’re not,” he added. “We have the ability to walk into a shop and make something. It’s hard to do that and not turn it into a product.”

Stephens and Gore are far from the first people to attempt to develop carbon rotors for use on bicycles. It has been attempted numerous times since the introduction of the disc brake, yet there are three interconnected problems that have yet to be satisfactorily addressed: rotor thickness, heat dissipation and consistent braking.

Note the lack of milled-out sections from the brake track. on steel rotors these are used to aid in dissapating heat (albeit at the expense of surface area used for braking). the siccc rotors ability to withstand higher temperatures and dissapate heat faster than their steel counterparts negates the need for these cutouts: note the lack of milled-out sections from the brake track. on steel rotors these are used to aid in dissapating heat (albeit at the expense of surface area used for braking). the siccc rotors ability to withstand higher temperatures and dissapate heat faster than their steel counterparts negates the need for these cutoutsNote the absence of holes in the brake track

The thickness, or lack thereof, of disc rotors is a significant hurdle. The materials used have to be quite stiff and, despite the fact the rotors are approximately 2-2.5mm thick, must do an adequate job of dissipating heat.

“If you jumped out to 4mm thick you could successfully use some of the materials that have been attempted, but then you would be creeping up to the weight of aluminum and steel rotors,” noted Stephens.

There’s also the mater of wet weather performance. This has been an issue for those riding road bikes with carbon rims for many years. The same issue has been a stumbling block for the development of carbon rotors. Moisture on the surface and in the carbon itself can significantly degrade braking power. A brief but unnerving “warm up” period is often needed before the pads take hold. Surface treatments are one possible solution, though they have a tendency to wear and degrade over time.

“Our goal from the start was to create a consistent, better-wearing, lighter-weight brake rotor,” said Gore.

The one-piece siccc rotor is constructed entirely of silicone carbide, ceramic and carbon material used for the braking track: the one-piece siccc rotor is constructed entirely of silicone carbide, ceramic and carbon material used for the braking trackWith an integrated spider, the SFL (So Freaking Light) rotor weighs a claimed 55g

“Clobbering them with Science”

The answers are as intertwined as the problems. Stephens and Gore claim to have developed a complex blend of materials, manufacturing and chemistry that make their rotors superior to everything else currently on the market.

“We can clobber them with science,” said Stephens.

It’s worth noting that there’s a lot more in Kettle Cycles’ SiCCC rotors than just carbon. The acronym used for the name of the rotors hints in a very general sense at the materials used: silicon carbide, ceramic and carbon. Silicone carbide is used to provide the bite. According to Stephens, this is the ingredient that has been missing from previous attempts. A ceramic compound is used to dissipate heat; the company claims that the SiCCC rotors can tolerate significantly more heat than steel rotors and do a better job of dissipating it, too. Finally, high-grade carbon fiber is used to form the rotor’s structure.

Here’s a video of the rotors in action.

Unlike carbon rims, which require specific pad compounds to achieve optimal performance, the SiCCC rotors can be used with standard sintered and organic pads. Stephens says the SiCCC rotors last significantly longer than steel rotors. “We haven’t worn one out yet,” he said.

Kettle Cycles is producing two versions of the SiCCC rotors. The one-piece design, dubbed SFL (short for So Freaking Light), weighs a scant 55 grams for a 160mm rotor, the company claims. The two-piece design uses a carbon spider riveted to the braking track and weighs 60 grams for a 160mm rotor. The 160mm one-piece version is expected to cost $99, while the 160mm two-piece model will retail for $79. The one-piece design is more expensive because it uses more of the costly brake track material. For comparison, a 160mm Shimano XTR rotor weighs 120g and costs $65.

A carbon spider riveted to the braking track adds weight but allows the company to use less of the costly brake track material: a carbon spider riveted to the braking track adds weight but allows the company to use less of the costly brake track materialThe two-piece rotor weighs 60g with a less-expensive carbon spider riveted to the brake track

Stephens expects the rotors to be available in late winter/early spring, with additional sizes to follow shortly thereafter. BikeRadar has a test pair coming, so check back to read our impressions this spring.

Kettle Cycles is not keen to stop at brake rotors; carbon cranks, dropper seatposts and carbon frames could all be future projects.

What do you think? Would you choose carbon rotors over steel?

You can follow BikeRadar on Twitter at twitter.com/bikeradar and on Facebook at facebook.com/BikeRadar.
You can also improve your fitness and train with us on bikeradar.com/training.

User Comments

There are 17 comments on this post

Showing 1 - 17 of 17 comments

  • Pointless, existing MTB brake systems work fine. Your tyre will skid before you exhaust the power of existing discs.

    Carbon tends to shatter and wear quicker.

  • If they work, then they make more sense on road bikes where the weight reduction adds more value, especially when discs are seen as adding weight. I'm certainly interested to see where these lead.

  • I agree, pointless, i think even in MotoGP they stick on steel rotors when its wet because the rotors can't get up to temperature to offer decent performance. with all the road disc trend i can't see people choosing marginal-at-best weight savings over consistent braking.

  • @gilesjuk

    Keep in mind there's a lot more going on with these rotors than stopping power. The rotors are lighter and the company claims they handle significantly more heat. We'll be testing whether or not they live up to those claims—as well as their durability—in the near future.

  • We have tested and put on hundreds of miles on a development version of our own flavor in the Oregon hills. Carbon rotors can offer significant gains if done correctly and I look forward to trying these ones out in the near future on my XC ride.

  • Makes sense to me that you'd want to give the tech a shot, but it's really the heat dissipation that I'm interested in. If it's no better than steel, then I don't feel it's good enough, especially if you want to re-purpose for road disk or touring (a situation where I've boiled the hydraulic fluid and had to dump the bike a couple of times)

  • @gilesjuk - Clearly they don't always work and this was the impetus for developing these discs. Besides, there was a time when people thought discs on MTBs was overkill because apparently V-brakes were more than enough. Anyone still believe that now?

    For every 100 dumb ideas that come out, there is often a genuine innovation that we may look back at in five years time and wonder how we lived without it.

  • interesting but the article reads like a cut and paste of a press release.

  • Why not develop Anti-lock Braking System for bikes? I think it would be more useful. But I think every development needs a chance to be tested. For now all I can say is this carbon rotor looks good.

  • I'd like to see more science, not just a statement “We can clobber them with science”

    I want to know how the rotors are made.

    The performance claims can hold true for the powered vehicle carbon reinforced carbon composite rotors where the material is not held together by a resin, but by graphite crystals - a product of pyrolisis and not related to how carbon fiber composite products, for example frames, are made.

    If they are using a resin system, then the discs will fail given enough heat stress. While carbon fibers themselves are excellent heat conductors, and can radiate it well due to them effectively being black bodies, the resin is a heat insulator, and unstable above its Tg (glass transition temperature).

    Another notable property of resins is that they are very heat reactive ie. they contract and expand depending on temperature, while Kettle Cycles claims less thermal expansion than steel.

    Thus, the rotors sound like they are a c-c composite, but I'd like them to confirm this. However if they are a c-c composite that is not exactly exotic anymore...

  • I was ready to dismiss these as a load of nonsense but the fact that you can use standard sintered pads rather than expensive proprietary pads changed that. If they really are strong enough to take a knock and more importantly don't wear out faster than steel discs using sintered pads in Peak District grit then I can see the advantage of them over standard rotors even though they are a bit more expensive. If they do generate a lot more friction then you can use smaller rotors which further reduces weight and the likelihood of them taking a knock.

    Also MotoGP bikes are totally different as they use carbon-carbon brakes which require huge heat to generate high friction, in the wet they use metal discs as they can't generate enough heat with carbon-carbon and as weight is less of an issue for motorbikes they can use thicker bigger discs to manage the heat produced.

  • How many people suffer with heat problems? It does exist, but is quite rare - at least in the UK, we don't have the opportunity to drag our brakes down 6000ft descents. A light weight solution will obviously benefit some, (and lightweight in general), but I think it will be a limited market.

  • They likely will remain true, unlike metal rotors...

  • Come on gilesjuk, do your six speed friction shifter work just fine too?

    I wan't them to keep develping things to make my bike better. My new bike is a 'little' better than my first dirt rig in '87!

    While you can't compare "apples to apples" with others, F1 cars, Moto GP/Superbike, snowmobiles, and M1A1 tanks use carbon brake rotors so developing a rotor to work well on a bike shouldn't be a problem. I've been waiting for one of the companies to develop a wider rotor brake system (5mm). Carbon rotors may allow them to do that.

  • @gilesjuk

    You're wrong on all counts. Engage brain before operating a keyboard !

  • Surely the disc is only a small part of the real issue here, Its claimed this was inspired by brakes that failed -How? and why will just changing to an exotic rota help

    TEMPERATURE is a problem, a sintered pad will work at higher temp but with such small amounts of compound before the backing plate there will be a piont where the thermo effiency of the compound will fail, but compounds that work at high temp dont work at low - look at the afore mention formula1 example, how hard they work brakes to maintain operating temp and we are talking maybe some of the same tech, thus can I have a pit wall for my bnext ride! just incase I am not perminantly at race pace :)

    FLUID is part of the problem, cycle brakes have little if any effective resevoir thus once over temp there is no effective way of cooling the hydrualics, let alone a method of regulating temp as the system runs. The majority of motorsport retirement are due to hydrualics problems

    CONTAMINATION- city use disc's regularly glaze giving little performance. It does not take much to affect the performance of the brake in this regard,

    WE all push our cycles beyound limits - whether for some thats genuinely a performance limit or for others a maintanence or service piont. the loads and enrgies that are put through a cycle can be massive, that lucky moment when you did'nt crash that unexpected heavy landing - that mucky grinding ride. How many actually check all their components and torque settings before putting the bike away for the next ride - From the sounds and looks of some others machines on the trails its no suprise of failure and everyones quick to blame equipment

    .

  • 55g for a 160mm disc is substantially heavier than the steel Jetblack discs I currently use. Also I can stop my 200kg motorcycle with one finger and steel discs so my 12kg mtb shouldn't really be an issue.

Post a Comment:

You need to login or register to post comments.

BikeRadar Partner Offers

MuchBetterAdventures

MuchBetterAdventures

-

Find the right cycling holiday for you with MuchBetter Adventures

Amazon.com

Amazon.com

-

Get great deals on cycle accessories with Amazon.com

Fitness Matches

Fitness Matches

-

Dating to get your pulse racing - get 50% off your first month with code FM50