The optimization of the brake systems is crucial for vehicle performance and safety of Formula SAE (FSAE) race cars. This study introduces a specialized brake test bench designed to enhance the understanding and testing of these systems. The bench integrates a rotating mechanical system mounting a brake disc-caliper group, which is driven by an electric motor, a pneumatic brake pedal assembly to simulate real braking conditions, and a comprehensive array of sensors that facilitate the measurement of critical parameters, such as rotation speed, braking torque, oil pressure, and disc temperature. Its structure, sensor integration, and control electronics are fully described, demonstrating the capability to replicate on-track scenarios in a controlled environment. The results underscore the utility of the bench in providing precise and consistent testing conditions essential for analyzing the efficiency, durability, and safety of the braking systems of FSAE race cars.

This paper details the conceptualization, design, topology optimization, manufacturing, and validation of a hydraulic brake caliper for Formula SAE race cars made of Scalmalloy^®, an innovative Al-Mg-Sc alloy which was never adopted before to manufacture a brake caliper. A monoblock fixed caliper with opposing pistons was developed, focusing on reducing mass for a fixed braking force. The design process began with a theoretical analysis to establish braking force and pressure requirements, followed by preliminary design and topology optimization. The caliper was then manufactured using laser powder bed fusion (LPBF). Comprehensive experimental validation, including testing with static and rotating brake discs on an inertial dynamometer, confirmed the expected caliper’s performance, with the results showing strong alignment with finite element analysis estimations. In particular, strain and displacement measurements showed excellent correlation with numerical estimates, validating the design’s accuracy and effectiveness.