SwissStop Catalyst rotor 6 hole 160mm

Powerful and durable

Powerful braking and high durability, available in five sizes for all applications from road to cyclocross, cross country and downhill to e-bikes. Different material thicknesses depending on the rotor diameter, targeted use of material at significant points and a friction ring made of SUS410 stainless steel increase braking performance and durability at the same time.

Swiss Engineering - the development of the Catalyst brake discs

At the beginning of 2015, the SwissStop engineering team carried out a series of laboratory tests on brake discs for bicycles. The engineers then constructed digital models of these rotors and simulated the same test conditions with sophisticated software. The comparison of data confirmed that the simulations were accurate and effective, and a number of digital prototypes were developed, thoroughly tested and evaluated.

The heat transfer in the individual models was measured extensively with the help of simulation software. Based on the respective relationship between convection, radiation, surface and weight, the optimal design was determined in order to achieve maximum heat dissipation and strength with minimum weight. The structure of each design was evaluated using braking forces ranging from normal hand strength to the theoretical maximum. Critical pressure points in the structure were identified in order to maximize the strength and rigidity of the rotor.

With the help of CFD simulations (Computational Fluid Dynamics), the air flow over the rotor surface and through the cut-outs was measured. A selection of profiles was tested to determine the effects of asymmetrical slots and to optimize the cooling effect of the airflow on the surfaces. The thermodynamic simulations, structural analyzes / material analyzes and fluid dynamic visualizations were carried out in cooperation with the institute of the University of Applied Sciences, HSR in Rapperswil.

The final design was confirmed and visualized by means of further thermal and structural simulations. A two-piece design consisting of a spider (7075-T6 aluminum alloy) and a SUS410 stainless steel friction ring was chosen to strike the right balance between light weight, reliable heat control and structural performance.

The laboratory test of the Catalyst Disc Rotor confirmed the results of the technical simulations. In the long-term load test, the Catalyst delivered outstanding results. While conventional brake systems wear out over time and the material ultimately fails (fading), the Catalyst offers a braking torque that remains constant over the long term. Further tests showed extremely effective heat management, significantly shorter braking distances, very little wear and tear, and structural durability under heavy braking. Overall, the Catalyst outperformed the current market-leading models.

Using practical tests with prototypes, the development team determined the optimal relationship between two essential but contradicting characteristics: braking performance and weight. A few carefully measured extra grams of material on the outer ring resulted in shorter braking distances. For certain rotor sizes, engineers added material to further improve performance and durability.

Highlights

• Optimal heat dissipation
• Reliable performance - from cyclocross to downhill
• Long service life, even under the most adverse conditions
• Compatible with organic and sintered brake pads
• Best performance in combination with SwissStop EXOTherm2 coverings
• Three small holes on each side of the rotor show exactly when the brake disc should be replaced
• Different material thicknesses (140mm - 1.85mm / 160mm - 1.80mm / 180mm - 1.90mm / 203mm - 1.95mm / 220mm - 1.95mm)
• 6-hole mount (screws optionally available)

scope of delivery

• 1 x SwissStop Catalyst brake disc (see item description for details)