The production process of the BSD system calipers begins with the moulding of the Ergal extruder, which takes place using presses exceeding 100 tons: the volume of the starting piece made of Ergal must correspond to the volume of the finished mould. For the actual moulding, the material is heated until it reaches a pasty state, it is inserted into the mould and, subsequently, pressed on several moulds to obtain a semi-finished product. At this point an aging heat treatment is carried out, which consists in allowing the component to cool slowly to increase its mechanical characteristics and surface hardness. The excess burrs are cut off and processed on C.N.C. machinery.
Starting from a forged piece has numerous advantages, first of all having the fibres of the material aligned during the various millings. In addition, less material is removed during processing, especially at critical points and, by not cutting the fibres, more mechanical strength and rigidity are ensured. This allowed the OTK technicians to reduce the size of the caliper while maintaining its mechanical resistance. This results in drier braking and greater performance stability on the track.