Design, Topology Optimization, Manufacturing and Testing of a Brake Caliper MADE of Scalmalloy® for Formula SAE Race Cars

This paper details the conceptualization, design, topology optimization, manufacturing, and validation of a hydraulic brake caliper for Formula SAE race cars made of Scalmalloy (R), an innovative Al-Mg-Sc alloy which was never adopted before to manufacture a brake caliper. A monoblock fixed caliper with opposing pistons was developed, focusing on reducing mass for a fixed braking force. The design process began with a theoretical analysis to establish braking force and pressure requirements, followed by preliminary design and topology optimization. The caliper was then manufactured using laser powder bed fusion (LPBF). Comprehensive experimental validation, including testing with static and rotating brake discs on an inertial dynamometer, confirmed the expected caliper's performance, with the results showing strong alignment with finite element analysis estimations. In particular, strain and displacement measurements showed excellent correlation with numerical estimates, validating the design's accuracy and effectiveness.