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A new "FUTURE Lab." which comprises a design department and a machining department has been set up.
The products we handle have expanded to the entire brake system. For that reason, we have set up the dedicated facility "FUTURE Lab. (Laboratory)" to handle more diverse analytical, design, and trial production operations. The design department, which handles everything from analysis work such as FEA (Finite Element Analysis) to design operations, as well as the machining department, which handles cutting operations centered on special processing work, have been relocated to this facility. 3D scanners, as well as computers for analysis and design work, are also being utilized as before in the design department.
Our new machining department is equipped with a 5-Axis CNC Machining Center manufactured by HERMLE, a leading German company that produces some of the most precise milling machines in the world, to carry out more advanced processing work for the components such as brake calipers of racing cars.
Its size also allows us to carry out processing for large-diameter wheels, and in addition to processing GT calipers that require precision, test processing of new technologies and trial production of new products can be performed more speedily. In addition to our mass-produced products, we will also be actively developing specially designed products that can meet the exacting requirements of the motorsports departments of automobile manufacturers for small-scale production.
A gift of ENDLESS's technical power, ceramic carbon rotors
In 2014 ENDLESS started on the design of ceramic carbon rotors in order to realize increased unsprung weight reduction and high-speed brake performance.
In order to realize 2/1000mm surface accuracy even in ceramic carbon rotors we adopted diamond polishing.
Also, because the surface temperature of ceramic carbon rotors exceeds 1000 degrees, we used stainless steel, with its strength retention, rather than aluminum for the brake bell housing. For the brake bell housing we strive for surface accuracy of 1/1000mm and cut it with no bends.
Even hard stainless steel normal bends a little when cut, but the ability to process it without bending is another technological power cultivated by ENDLESS.
Brake bell housings made from stainless steel increase weight, and making them lighter without decreasing the strength and realizing conflicting performance goals can be called another of ENDLESS products' merits.
Sintered compound brake pads using only metal for the pad material are high performance and high durability brake pads even used by the Shinkansen. In overseas endurance races such as WEC, the majority of teams use ENDLESS's sintered compound brake pads.
In order to manufacture sintered compound brake pads, a unique and specialized autoclave is required. In ENDLESS's research and development labs we have installed several specialized autoclaves. In addition to these facilities we also use the unique know-how we have cultivated from past experience to manufacture sintered compound brake pads with high braking performance.