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Design and Structural Finite Element Analysis of Brake Caliper for Directed Energy Deposition

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Abstract:

Additive Manufacturing (AM) has transformed modern engineering by enabling the creation of complex and customized components with exceptional precision and minimal material wastage. This innovative manufacturing technique is increasingly applied in the automotive industry, where it plays a key role in producing lightweight, efficient, and high-performance parts, such as brake systems, engine components, and structural elements. AM offers unmatched flexibility, allowing engineers to move beyond the limitations of traditional manufacturing methods and develop designs that enhance both performance and sustainability. This work leverages AM to design brake caliper and brake pads with vent holes, which are essential for improving heat dissipation and braking efficiency. The process begins with the design phase, where the brake caliper and several brake pad models, featuring unique vent hole geometries, are developed using SolidWorks. These designs are then subjected to motion studies to evaluate their performance in conjunction with rotating disc brakes, ensuring optimal functionality under dynamic conditions. Finally, Structural Finite Element Analysis (FEA) for brake caliper is performed to assess stress distribution and deformation under braking loads. This analysis identifies the most robust and effective designs, ensuring they can withstand operational forces while maintaining reliability. This study demonstrates how advanced technologies like AM, combined with design and simulation tools, can lead to significant innovations in automotive braking systems. By integrating cutting-edge techniques, this work covers the way for creating more efficient, sustainable, and high-performing components in the automotive sector.

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Periodical:

Engineering Headway (Volume 41)

Pages:

87-102

DOI:

https://doi.org/10.4028/p-G2JbAQ

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Online since:

July 2026

Authors:

Smaran Kalakoti*, Tanyu Donarld Kongnyui, Jayanth Kumar Madem, Debashish Gogoi, Nidhi Yadav, Manjesh Kumar

Keywords:

Additive Manufacturing, Brake Caliper, Brake Caliper Pad, Design, Motion Analysis, Structural FEA

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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