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MEng Capstone: Development of High-Temperature-Resistant Traceability Solutions for Brake Parts

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Wayne Toh

Project Timeline

Sep 2025 - Current

OVERVIEW

Braking systems are critical safety components for sports cars and other high-performance vehicles. Ensuring the reliable operation of braking systems under all environmental and mechanical conditions is essential, and material failure or manufacturing defects cannot be tolerated. Simultaneously, manufacturers face the challenge of reducing production costs while maintaining quality, safety, and performance standards. Given that brake calipers and pads are safety-critical components, traceability throughout the entire manufacturing process is vital. Each brake part must carry a unique identifier that can be tracked from raw material through production, heat treatment, surface finishing, and final assembly. However, many stages of brake caliper manufacturing — including casting, heat treatment, surface oxidation, and painting — expose components to extreme temperatures, mechanical forces, and surface alterations, making it difficult to apply durable, readable, and tamper-proof identification marks.

HighlightS

Conducting benchmarking studies of engraving, laser marking, and RFID systems for material compatibility, durability, and cost efficiency.

Performing market and literature analysis to identify opportunities for innovation in brake component traceability.

Working with multinational teams to align research insights with Brembo’s industrial production processes and quality standards.

Supporting the development of a proof-of-concept framework for next-generation marking and identification systems.

SKILLS

Manufacturing Test and ExperimentationDie CastAnnealingHeat TreatmentCFDCADLeadershipProject ManagementResearch and Development

Additional Details

For my Masters of Engineering Capstone Project at UC Berkeley, my team and I (5 members) are involved in an Industry project with Brembo. We were required to sign a non-disclosure agreement so I will outline our current goals and tasks.

The project begins with a comprehensive market and literature review of existing marking technologies, including engraving, laser marking, RFID chips, and other innovative traceability solutions. The goal is to benchmark each method's advantages, limitations, and compatibility with different stages of brake caliper and pad production — from initial casting to final assembly. This project is carried out in collaboration with Brembo, the global leader in high-performance braking systems and a long-standing partner of UC Berkeley. My team works closely with Brembo’s technical teams in Italy and the Bay Area, with direct access to materials and production processes. The combined expertise of Brembo’s industrial teams and UC Berkeley’s research community provides a unique opportunity to develop advanced, cost-effective, and reliable marking solutions for brake calipers, pads, and other safety-critical manufacturing components. I’m also working in a project management role, taking lead in seeking out industry supplier to create opportunities to get the project off the ground, ensuring everybody’s skills and desires are aligned with what they’re working on, and continually doing research to ensure that our design direction actually solves a problem and will be useful. This project is ongoing and is still in the literature review and market analysis phase.



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