Blue Print Brake Discs – Uncompromised Precision

From raw material to precision product! In this article, we discuss the process and materials used to create Blue Print Brake Discs in OE-matching quality.

As the brake disc rotates with the wheel, it is clamped by the brake pad friction material, fitted to the caliper from both sides by pressure from the piston(s) and decelerates the disc rotation, slowing down and stopping the vehicle.

This action creates a lot of thermal energy, producing heat. The amount of heat generated depends on the speed and weight of the vehicle and how hard the brakes are being applied.

Prolonged, heavy, or aggressive braking can cause the temperature of the brakes to rise so high that they start to become less effective and fade. When this happens, the driver has to press harder on the brake pedal to slow the vehicle down.

It is important, for safety reasons, to consider the construction of the brake disc and its ability to dissipate heat quickly and effectively in the right areas. To do this, the disc must be of the right weight, mass and thickness and must be made of the correct material which includes a high carbon composition.

From Raw Materials to Precision Product

Blue Print brake discs are manufactured to the highest standards, using a grey iron smelting process of a mixture of new and recycled materials, combining metal composites. Choosing the right material is critical to the quality and operation of the brake discs for each vehicle application.

A number of cast iron chemical compositions are used. These are enriched with alloy components – such as molybdenum, copper, chrome, titanium, etc. – to enhance tensile strength and hardness for optimal performance.

The molten metal is heated to 1,360 – 1,460°C; each batch is tested before it is poured into precisely made sand moulds to form the raw moulded brake disc. The casting process must give an even pearlitic matrix microstructure, containing a substantial content of laminar graphite. (Fig.1) This gives a high steel tensile strength, meeting the metallurgical requirements of unalloyed and low alloyed grey cast iron used for castings required by vehicle manufacturers.



The new part is cooled and any excess sand removed. It is inspected for any moulding faults before being precisely machined, drilled and balanced to minimise resonance and torsional vibration. The disc surface is given a precision cross-ground finish, enabling a reduced bedding in period. Each disc is stamped with a range of identification numbers, the Blue Print reference and the minimum thickness before replacement is required. Finally, an anti-corrosion grey epoxy resin coating is applied, which provides long-lasting performance and appearance.

The final result is a brake disc with high thermal efficiency, optimal dampening properties and the prevention of brake vibrations.

Why Blue Print Brake Discs?

  • Extensive Range – An extensive All-Makes range of more than 1,700 brake friction components for Asian and European vehicle applications. Coverage of over 96% of all popular passenger cars and LCVs on European roads (launched from the year 2000 and onwards)
  • Cataloguing – Easy to find the right discs you need by using our online catalogue Partsfinder, search by VRM or Vehicle Make & Model. We use Official Manufacturer Electronic Parts Catalogues to ensure ultimate levels of accuracy within our cataloguing.
  • Disc Finish – All brake discs come standard with a cross ground finish, and all non-contact surfaces are painted with an epoxy resin.
  • Packaging – All Blue Print brake discs come in special packaging illustrated by technical drawings and are ECE R90 compliant when required.
  • In Pairs – All brake discs meet predefined criteria and are packaged in pairs with a combined weight limit of 20kg. Discs weighing more than 10kg each – or are sold with studs, integral bearings, are hand specific, etc. – are packaged individually.

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