College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
Date
3-2026
Primary Advisor
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
Brakes are the most critical safety system on any performance vehicle, and as Cal Poly Racing transitions their Formula SAE car from a single rear motor to a four-in-wheel motor setup with regenerative braking, the team identified an opportunity to develop a bespoke brake caliper tailored to their specific needs. This document outlines the research, design, manufacturing, and validation of custom front brake calipers designed to improve upon commercial motorcycle calipers in key areas such as serviceability, mounting rigidity, thermal behavior, mass, and hub motor integration. The resulting design is a two-piece, four-piston, radially-mounted aluminum caliper featuring titanium pistons, toolless pad removal, and mirrored bleed ports, which has been fully manufactured, assembled, and bench-tested for structural and sealing integrity. On-car testing remains as the final validation step ahead of competition operation.
URL: https://digitalcommons.calpoly.edu/mesp/868
Included in
Computer-Aided Engineering and Design Commons, Manufacturing Commons, Other Mechanical Engineering Commons