Carbon Brake Discs
Delamination-Free Racing & Aerospace Performance
Wyken Engineering delivers precision carbon components, such as carbon brake discs, using advanced ultrasonic drilling and specialist composite technology. Trusted by championship racing team suppliers and aerospace manufacturers, our facility ensures delamination-free performance, rapid turnaround, and technical partnership for demanding applications.
Carbon brake discs represent the pinnacle of braking technology—offering exceptional performance-to-weight ratios, fade resistance, and thermal stability impossible with conventional materials. However, machining carbon composites presents significant challenges: conventional processes cause delamination, fibre pull-out, and subsurface damage that compromise structural integrity and performance.
With over 70 years of precision engineering experience and proprietary ultrasonic machining technology, Wyken Engineering has become a trusted partner for motorsport team suppliers, aerospace manufacturers, defence programmes, and advanced engineering sectors requiring carbon brake discs that perform without compromise.
Ultrasonic Machining Technology
Wyken Engineering’s proprietary ultrasonic-assisted drilling fundamentally changes how carbon brake discs are manufactured. Our 20kHz vibration technology eliminates the delamination and fibre damage conventional drilling inevitably causes.
Ultrasonic vibration reduces cutting forces by up to 60%, preventing layer separation and matrix cracking. This preserves fibre orientation—ensuring carbon brake disc strength matches design intent—and eliminates subsurface damage that creates hidden failure points.
Our ultrasonic technology enables intricate ventilation channels and cooling patterns impossible with conventional drilling, optimising thermal management for sustained performance. Championship racing teams specify proprietary cooling geometries providing competitive advantage—our capability manufactures these complex patterns reliably and repeatably.
The technical advantages translate directly to performance: stable friction properties critical for driver confidence, reduced bedding-in cycles from 50+ laps to 10 laps (competitive advantage during limited practice time), extended service life reducing replacement frequency, and temperature resistance maintaining performance through repeated extreme thermal cycling.
Specialist Carbon Facility & Materials Expertise
Manufacturing carbon brake discs demands dedicated infrastructure preventing contamination and ensuring consistent quality. Wyken Engineering operates a purpose-built carbon processing facility isolated from metallic machining, with advanced HEPA filtration managing carbon dust and environmental controls preventing moisture absorption.
Our carbon facility includes CNC machining centres specifically configured for composite processing, purpose-built tooling integrates ultrasonic vibration, and specialist diamond-coated cutting tools deliver optimal results. Precision grinding capabilities provide final surface finishing when required.
Our AS9100 Certification ensures aerospace quality management—every brake disc meets flight-critical standards. Complete traceability links raw materials through machining operations to finished components, supporting regulatory compliance and forensic investigation if required.
Ready to discuss your Carbon/Carbon brake requirements?
Contact our technical team for application-specific consultation.
Material Systems
Carbon-Carbon Brake Discs offer extreme temperature performance with friction properties that improve at elevated temperatures. Applications include single seater racing, endurance racing, championship categories, and military aircraft requiring extreme braking performance for short-runway operations.
More than 3,000 carbon brake discs manufactured with zero documented delamination failures across motorsport, aerospace, and defence applications. This track record includes championship wins across multiple racing categories, airworthiness certification support, and MOD approval for defence vehicle brake systems.
Quality Verification
AS9100 documentation provides comprehensive traceability including manufacturing records, inspection reports, material certificates from certified suppliers, and non-conformance records. This supports regulatory audits, championship scrutineering, warranty investigation, and continuous improvement.
Sector-specific compliance: racing teams receive documentation supporting technical regulations, aerospace manufacturers receive certification packages for airworthiness approval and defence programmes receive MOD-compliant documentation.
Reliable Production & Technical Partnership
Wyken Engineering provides scheduled production planning aligned with racing season calendars, aircraft maintenance windows, defence programme timelines, and performance upgrade schedules. Our engineering team offers direct communication: design review collaboration, testing support coordination, documentation alignment with regulatory schedules, and collaborative technical problem-solving.
We optimise production batching for economic manufacturing, material utilisation, process consistency through statistical control, and flexible capacity accommodating specification changes. Clients receive direct access to manufacturing engineers—technical questions receive technical answers without sales intermediaries.
This approach has built long-term partnerships with racing team suppliers returning season after season, aerospace manufacturers trusting us with flight-critical components, and defence programmes requiring reliable supplier relationships. We understand carbon brake discs are integral to vehicle performance, operational safety, and programme success.
Exploring a new Carbon brake disc project?
Speak to our engineering team about prototyping.
Why Choose Wyken Engineering?
Over seven decades of precision engineering combining proprietary ultrasonic technology with dedicated carbon facilities and comprehensive quality systems satisfying motorsport, aerospace, and defence applications.
Proven Technology: Ultrasonic machining delivering delamination-free performance across 3,000+ brake discs with zero structural failures.
Specialist Infrastructure: Dedicated carbon facility with contamination controls, environmental management, and aerospace-certified quality systems, supported by our comprehensive CNC turning and finishing services.
Materials Expertise: Comprehensive knowledge of carbon-carbon composites across motorsport, aerospace, and defence applications.
Technical Partnership: Engineering consultation from application analysis through specification optimisation to production support—we’re partners in brake system success.
Whether you need carbon brake discs for championship racing, commercial aviation, military aircraft, or defence vehicles, Wyken Engineering delivers precision, performance, and partnership. Our Warwickshire facility provides rapid access across the UK.
Ready to discuss carbon brake disc requirements?
Contact Wyken Engineering for technical consultation and quotation.
