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Brakes for All Makes!

Why Blue Print?

Complete All-Makes range of more than 3,400 brake friction components for Asian and European vehicle applications with a coverage of over 98% of all passenger cars and LCVs on European roads – for brake discs and pads launched after the year 2000

All components are developed and manufactured to meet OE specifications to be direct replacements with rigorous and systematic quality checks to ensure for the continuous supply of quality products 

Continuous research and constant development of range with the use of Official Manufacturer Electronic Parts Catalogues ensure ultimate levels of accuracy and keep pace with every new vehicle released into the market according to ‘Fast to Market’ philosophy 

Guarantee an excellent level of comfort and performance all while ensuring a safe journey 

Confidence that brakes will fit 'Right First Time.'

Blue Print Brake Friction Promotional Video



The Blue Print Manufacturer Guarantee:

Our Quality Promise - Your Added Value

In order to underline our high product quality standards, we are providing a 3 year manufacturer guarantee for all of our replacement parts.

Quality of the Highest Standard

Quality from the Start

Since friction braking parts are critical, safety related products, quality is of the utmost importance. As a means of guaranteeing the continuous provision of high-quality components, each stage of the production process undergoes sample analysis controlling for conformity and accuracy.

This ensures that regulation standards are met –´or even exceeded – and that everything is being produced to the correct specification.

It’s All About the Right Mixture

It all starts with product research – analysing the original part and sample production and testing. When a new product is developed, the raw ingredients in the production process are paramount for the correct vehicle application and load.

For each part, the materials are selected for optimal balance between friction coefficients, comfort,and wear behaviour. This also includes key factors that also affect noise, vibration and harshness characteristics.

Testing, Testing

Each new brake part is put through dynamometer testing for braking, noise and wear performance. Physical and chemical tests are carried out for hardness, shear strength and compressibility – meeting numerous ISO, SAE and JASO standards.

Additional checks and tests are performed for brake fade, thermal conductivity and wear behaviour.

Approval Needed

Each new part is required to be inspected and tested by a type approval authority with internationally recognised testing and certification. These independent testing companies check the new parts in accordance to the standards described in the ECE R90 regulations for shear strength, pressure, speed sensitivity and compressibility.

Once approved, the testing company requests an approval number and a certificate from the governing body.

 

The Braking System

There are three basic, dynamic elements of every vehicle: accelerating, changing direction and stopping. The function of stopping being controlled by the braking system is one of the most important, safety related systems in any vehicle and is indispensable for active and passive passenger safety and security.

The Power of Friction

It is the power of friction that changes kinetic energy into a thermal energy. Friction is the resistant force which is generated when two moving objects make contact.

When the driver presses the brake pedal, the delivered pressure is about 30 times that of the driver's foot. In other words, the strength of the driver's foot at the brake pedal - which is approximately 15 kg - is amplified to about 450 kg of braking force.

Performance Requirements for Brakes

Additionally, when braking at 100 km/h, this friction can generate enough heat to boil two litres of water in three seconds.

Noise, Vibration & Harshness in Braking

Do You Hear That?

Brake noise is created by a high pitch vibration which you can hear.

Imagine tracing the rim of a wineglass containing water with a finger. A vibration is created by the friction caused by the finger causing the glass to resonate. This produces a sound. This is the same principle that is applied to the noises and vibrations that are generated by the friction between brake pads and discs.

All Aspects Count

There are many factors that must be considered to suppress brake noise and vibrations. These include the quality of materials, the shape and torsion of the components, the driving environment, vehicle speed and brake temperature.

Noise is often caused from the vibration of the pad against the disc where full contact is not taking place or failing or faulty parts such as shims and pins which have lost their tension and create sound waves. These sound waves can either be the high pitched vibrations you are able to hear or a low pitch vibration which you can feel.

Minimising the Unpleasant

During the development of a new Blue Print brake pad, many technologies are used in order to improve comfort for both the driver and passengers by minimising the potential for these unpleasant vibrations and noises.

Blue Print matches or exceeds the specifications of the OE brake pad, therefore retaining the original manufacturer’s benefits and features – such as chamfering and/or the addition of slots to ‘tune’ the pad so it makes less noise.

There are also various types of shims which may be fitted to the steel backing plate to dampen vibrations between the pad and caliper. These shims act like a cushion; they absorb noise producing vibrations.

 

Servicing the Brake System

  1. Examining the condition of the brake calipers and carriers, plus any other hardware to see if they are worn, ceased, or corroded.
  2. When fitting new brake pads, make sure all corrosion is removed from the pad and caliper abutment points and fit the new brake hardware.
  3. Lubricate the abutment points to ensure free movement and efficient braking by using the Blue Print anti-seize ceramic paste.
  4. Avoid the use of copper grease as this can potentially affect ABS signals and encourages galvanic corrosion. It also prevents the brake pad from moving freely, which can also be a source of noise.
  5. If the brake discs are heavily scored or lipped, they, too, will need replacing as the rough surfaces cause noise.
  6. Make sure the hubs are clean and check for lateral runout by using a dial test indicator.
  7. Check the tolerances with the vehicle manufacturer’s data before fitting the new discs. It is important to clean the hub surfaces before replacing the brake discs, otherwise brake judder could occur.

For quiet, effective brakes, make sure you fit quality braking parts and the appropriate accessories from Blue Print’s extensive range whenever you service the braking system.

Brake Discs

The Heat is On

As the brake disc rotates with the wheel, it is clamped by the brake pad friction material, fitted to the caliper from both sides with pressure from the piston(s) and decelerates the disc rotation, therefore slowing down and stopping the vehicle. This action creates a lot of thermal energy, producing heat. The amount of heat generated depends on the speed and weight of the vehicle and how hard the brakes are being applied.

Heat can cause the brakes to become less effective and fade as a result of prolonged, heavy, or aggressive braking. As a result:

  • Overheated discs can suffer from excessive wear, cracking, Disc Thickness Variation (DTV) and potential break-up.
  • The driver may have to press harder on the brake pedal to slow the vehicle down.
  • In extreme cases, there may be a point where the brakes get so hot that they cannot generate enough friction regardless of how hard the brake pedal is pressed.

However, as main components are exposed to the atmosphere, this heat can be diffused efficiently – thus reducing brake fade.

It is important, for safety reasons, to consider the construction of the brake disc and its ability to dissipate heat quickly and effectively in the right areas. In order to do this, the disc must be of the right weight, mass and thickness and must be made of the necessary material which includes a high carbon composition.

An extensive range of over 1,700 brake discs, covering more than 96% of all common Asian and European vehicles in Europe year 2000 or newer.

From Raw Materials to Precision Product

Blue Print brake discs are manufactured to the highest standards, using a grey iron smelting process consisting of a mixture of new and recycled materials combining metal composites. Choosing the right material is critical to the quality and operation of the brake discs for each vehicle application.

A number of cast iron chemical compositions are used. These are enriched with alloy components to enhance tensile strength and hardness for optimal performance. Such components include:

  • Molybdenum
  • Copper
  • Chrome
  • Titanium
  • Etc.

 

 

Brake Discs with Integrated Wheel Bearings

Some vehicle applications – particularly Renault and Peugeot/Citroën – use brake discs with an integrated wheel bearing on the rear axle.

This type of assembly, established by the vehicle manufacturer, results in significant weight savings since the brake disc also becomes the wheel hub. This type of disc/bearing assembly is equipped with a phonic wheel – or a magnetic encoder for the wheel speed sensor to establish acceleration and deceleration – to monitor wheel speed. The wheel speed signal is transposed by the control units of the vehicle and used for the operation of the ABS and other functions that control the stability of the vehicle.

This preassembled part makes replacement easier and quicker for the workshop, ensuring a perfect fit and eliminating the risk of mounting a bearing with incorrect clearance or seal positioning. This is essential for a safety component’s operation and security.

Brake Pads

Brake Pads for Optimal Safety & Comfort

Blue Print aims to find the optimal solution for safety, comfort and efficiency for each brake pad application. Every brake pad set features high shear strength, an excellent stability friction coefficient, low noise levels and minimum vibration which provides a secure feeling for the driver at the brake pedal. This makes braking progressive and comfortable.

A decisive factor for optimal brake pad quality is the individual components which form each pad. Combining these elements provides reliability and safety.

  1. Friction Material Features: Specifically matched to particular vehicle type and model.
  2. Intermediate Layer Features: Optimise compressibility reduces heat transfer.
  3. Adhesive Features: High shear strength; bonds friction material to the pad carrier.
  4. Backing Plate Features: High material strength.
  5. Shim Features: Reduces brake noise.

A complete range of over 1,250 brake pad sets for Asian and European vehicle applications, covering more than 96% of popular vehicles in Europe launched from the year 2000 or newer.

Friction Material

Brake pad friction materials are required to perform under a variety of conditions including:

  • Vehicle speed
  • Laden weight
  • Vast temperature changes from brake usage
  • Humidity
  • Water
  • Road Surface Conditions

As a result, a brake pad must have excellent mechanical strength and durability for a long service life.

The friction material is made from a blend of many different raw materials depending on the vehicle application. The raw materials are divided into three categories: bonding material, stiffener and friction adjustment material.

Brake Pad Manufacturing

After the friction material has been chosen, the production process starts with fine blanked back plates. These back plates are shot blasted and degreased to increase the adhesion of the glue onto the back plate. Afterwards, the pad mixture is pressed onto the back plate. The combined elements are then permanently unified in the curing furnace.

An optimal surface is created by slotting and chamfering the friction material. This is followed by an anti-corrosion treatment of powder coating for the brake pad. Hardware is then added as required – such as the fitment of shims, warning wires and springs. 

Brake Drums & Brake Shoes

How They Function

Typically, drum brakes are used in the rear braking system of smaller passenger cars; they also have the proven ability to serve as a parking brake, which can be combined within a disc brake on some larger vehicles.

When the brake pedal is applied, the wheel cylinder pistons press against the brake shoes and force them outwards. As a result, the friction that is generated from the brake linings - against the inner surface of the drum - decelerates and stops the vehicle.

An excellent range of over 130 brake drums and 320 brake shoes covering more than 14,800 Asian and European vehicles applications.

Leading or Trailing

There are three types of drum brake designs subject to how the brake shoes are pressed onto the drums:

  1. leading/trailing
  2. twin leading
  3. duo-servo

The most common type used today on passenger cars is the leading/trailing type. The leading shoe is a term that refers to the shoe that moves in the direction of rotation when it is being pressed against the drum. The other shoe is called the trailing shoe. The leading shoe is pressed in the same direction as the rotation of the drums. This rotation helps to press the shoes against the drum with greater pressure for a stronger braking force. This is called the servo effect which gives the braking force to drum brakes in order to decelerate and stop rotation.

Brake Drum Manufacturing Process

Smelting - Combining and Conforming

The manufacturing process of high-quality Blue Print brake drums and shoes is very similar to that of brake discs and pads.

It starts with a grey iron smelting process of a mixture of new and recycled materials combining metal composites conforming to material grade EN-GJL-200.

 

Molten Metal - High Heat Needed

The molten metal is heated to 1,360 – 1,460°C. Then, each batch is tested before it is poured into precisely made sand moulds. This forms a raw moulded brake drum with a very high content of laminar graphite.

It is cast in a uniform pearlitic matrix microstructure. This gives a high steel tensile strength, meeting the metallurgical requirements of unalloyed and low-alloyed grey cast iron used for castings required by vehicle manufacturers.

 

Cooling - Finishing Touches

The new part is cooled and any excess sand is removed. It is inspected for any moulding faults before moving on to be precisely machined, drilled and balanced to minimise resonance and torsional vibration and to give a precise fit.

Each drum is finished with an anti-corrosion grey epoxy resin coating, ensuring long-lasting performance. It is stamped with a manufacturer’s identification, Blue Print part number and minimum wear thickness.

Brake Shoe Manufacturing Process

Degreasing & Welding - Starting with Fine Blanks

The production process of brake shoes starts with the fine blanked parts being degreased and spot welded together to form the shoe.

 

Shot Blasting -  Increase the Adhesion

The newly constructed shoe is shot blasted to increase the adhesion of the glue onto the shoe.

  

Finishing Touches - Onto the Shoe

Afterwards, the friction mixture is pressed onto the shoe with a pressure of 250 – 400 bar at 230 °C. The new part is then permanently unified in the curing furnace.

In order to ensure an accurate fit when installed onto the vehicle, an optimal surface is created by chamfering the friction material. This is followed by an anti-corrosion lacquer treatment. The new brake shoe is printed with the Blue Print part number and markings, homologation numbers and other vehicle and material references before being inspected and packed with any accessories and fitting instructions.

Best Practice in Brake Pad and Disc Replacement



Braking Parts Specialised for Asian Vehicles 

Going beyond the full selection of dry braking components for All-Makes, Blue Print – as a specialist for parts for Asian vehicles – has the complete solution for the remainder of the braking range for Asian applications.

There are currently more than 3,200 parts in the braking range alone – covering over 70,000 applications – giving you an unrivalled breadth and depth of coverage for Asian vehicles.

From fitting kits for brake pads to ABS sensors, Blue Print is Your One Stop Shop for Your Asian Vehicle Braking Needs!

To get more information about the full Blue Print braking range for Asian vehicles, visit our online catalogue at partsfinder.

A Change in Automotive Propulsion

As global emission laws are getting stricter, car manufacturers are reacting by producing new models of vehicles that are either electric or hybrid.

Blue print has followed this perpetual evolution of automotive technology for many years, continuously cataloging and introducing brake pads and discs to the range as the vehicles are being launched.

You can view our full range of parts for electric and hybrid vehicles at partsfinder.