Step 1
Creating a manufacturing batch
Before a production batch ever reaches the shop floor, we follow a thorough and carefully coordinated process to ensure everything is set up for success. Our production engineering team dives into the details: reviewing manufacturing drawings, verifying production routing, checking materials, prepping tooling, and machine programs. All to make sure the transition to manufacturing is seamless and efficient.
Step 2
Ensuring Full Traceability
We use high-strength 7075-T651 aerospace-grade aluminium for our caliper bodies. Chosen for its exceptional performance and durability. Our trusted, approved suppliers provide the material in billet form, each accompanied by a certificate of conformity that traces the aluminium all the way back to the mill and the exact batch it came from.
Once received, every billet is clearly marked with its traceable identification number, which is then machined directly into the caliper during production. This meticulous approach means that if a caliper is ever returned, we can instantly trace it back to its origin. Verifying the material’s authenticity and isolating any other components made from the same batch.
Step 3
CAD Manufacturing Process
Our CNC machines are precisely programmed by our dedicated CAM engineering team using the latest Edgecam software. This advanced software allows us to create highly optimized toolpaths tailored specifically for machining our aluminium brake calipers, ensuring exceptional accuracy, surface finish, and repeatability. By combining expert programming with state-of-the-art CNC technology, we consistently deliver calipers that meet the tight tolerances and performance standards demanded in high-performance braking systems.
Step 4
CNC Machining
Using a suite of advanced HAAS 3- and 5-axis high-speed machining centres, we precision-machine our aluminium calipers to the highest industry standards. These state-of-the-art CNC machines allow us to produce complex geometries with exceptional accuracy, consistency, and surface finish. The multi-axis capability enables us to machine multiple features in a single setup, reducing handling time and ensuring each caliper meets our exacting tolerances for performance, strength, and reliability.
Step 5
Clocking and Scanning
We’ve built a rigorous Shop Floor Data Collection (SFDC) system that keeps our production process sharp, efficient, and continuously improving. With real-time tracking of every production batch, we always know exactly what’s happening on the shop floor. If your caliper is being made to order, we can pinpoint its exact stage in the process and even tell you how much machining time remains.
Step 6
Final Inspection
Once machining is complete, every caliper body undergoes a thorough inspection using a range of advanced techniques and equipment. We utilise high-precision Coordinate Measuring Machines (CMM) to verify key dimensions with an accuracy of up to 5 microns.
This ensures each component meets our exacting standards. This meticulous quality control process guarantees that every caliper we produce delivers the performance, safety, and reliability our customers expect.
Step 7
Anodising
Once machined, our calipers are sent to an approved anodising specialist, where they undergo a full sulphuric anodising process. This not only enhances the appearance but also provides a tough, corrosion-resistant layer that protects the aluminium and extends the life of the caliper.
We also give you plenty of options to make your calipers your own. While classic Black and Silver finishes are our most popular and held in stock, We also offer a bold range of custom colours. These include Blue, Red, Yellow, Green, Purple, Orange, and even Gold! Custom colours take a little extra time, with a typical lead time of 2–3 weeks, but the result is well worth the wait.
Step 8
Laser Marking
Next we laser mark offer each caliper with the BCC logo.
Restoration shops can proudly display their logo on every caliper, adding a layer of authenticity and brand recognition.
Step 9
Assembly
We normally only assemble calipers once a customer places an order so they can select the colour, artwork and assembly components of their choice. We have several highly skilled assembly staff that use our dedicated caliper assembly area with various checks to ensure nothing is missed.
Step 10
External Components
Brake pads from EBC or Mintex, the highest quality pipes and adaptors from Automec, modern fluid and dust seals from Liberty, and specialist high specification Holokrome bolts. We take great care in selecting only the best quality assembly components that compliment our calipers.
Step 11
Testing
We test every caliper we produce using our dedicated pneumatic test rig which pressurises the caliper and monitors any reduction in the pressure to identify any leaks. The software will tell us if the caliper passes or fails the test and if it passes it will produce a certificate that we include in the box.
Step 12
Boxing
We carefully pack your new brake kit into bespoke boxes to ensure they are received in pristine condition.
