Aerospace Derived Technology

Manufacturing
Process

CTE's proprietary 5-step process transforms T700-grade continuous carbon fibers into high-performance Carbon/Silicon Carbide (C/SiC) ceramic brake discs — delivering 50% weight reduction and zero thermal fade at temperatures exceeding 1000°C.

T700Continuous Fiber Grade
1500°CLSI Reaction Temp
2800+HVSurface Hardness
50%Weight Reduction
1000°C+Zero Fade Threshold
Proprietary Technology

Manufacturing process

Five stages, one continuous vertically-integrated line — no external sub-contractors at any point.

  1. 01
    T700 Continuous Fiber3D Needle-Punching

    3D Fabric Preforming

    T700-grade continuous carbon fibers are woven into a three-dimensional reinforcing matrix using patented needle-punching technology. Unlike discontinuous T300-grade fibers used in standard OEM discs, the continuous long-fiber architecture ensures isotropic strength and superior delamination resistance.

    CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — Step 1: 3D Fabric Preforming with T700 continuous carbon fiber
  2. 02
    Vacuum CarbonizationCVI Densification

    Carbonization & Chemical Vapour Infiltration

    The preform undergoes high-temperature vacuum carbonization to pyrolyze the fiber binder, followed by CVI in which hydrocarbon gases decompose and deposit a dense pyrolytic carbon (PyC) matrix, producing a Carbon/Carbon (C/C) composite intermediate.

    CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — Step 2: Carbonization and Chemical Vapour Infiltration (CVI)
  3. 03
    1500°C Molten Silicon>2800 HV Hardness

    Liquid Silicon Infiltration

    The C/C preform is infiltrated with molten silicon at 1500°C in a vacuum furnace. Silicon reacts with free carbon to form Silicon Carbide (SiC) in-situ, converting the matrix into a C/SiC ceramic composite with hardness exceeding 2800 HV.

    CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — Step 3: Liquid Silicon Infiltration (LSI) at 1500°C
  4. 04
    ±0.05mm ToleranceG2.5 Dynamic Balance

    Precision Machining

    CNC diamond grinding achieves final dimensional tolerances within ±0.05 mm, followed by ultrasonic drilling for ventilation channels. Dynamic balancing is verified to G2.5 standard.

    CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — Step 4: Precision CNC Diamond Grinding and Machining
  5. 05
    50% Weight ReductionZero Fade to 1000°C+

    Quality Inspection & Application

    Each disc passes dimensional, porosity, and dynamic balance inspection. The finished C/SiC disc delivers 50% weight reduction versus cast iron, stable friction from cold start to above 1000°C, and zero thermal fade under repeated race-condition stops.

    CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — Step 5: Final Quality Inspection and Application
Dimensional & balance check

Every disc is verified for dimensional accuracy, porosity, and dynamic balance before leaving the line.

Thermal performance verified

Stable friction from cold start to above 1000°C, with zero thermal fade under repeated race-condition stops.

CTE C/SiC Carbon Ceramic Brake Disc Manufacturing Process — finished disc, T700 continuous fiber, Liquid Silicon Infiltration at 1500°C, hardness >2800 HV
CTE C/SiC Carbon Ceramic Brake Disc — Aerospace-derived technology engineered for hypercars and motorsport applications.

CTE Carbon: Engineering the future of braking

Aerospace-Derived Technology  |  Race-Proven Performance

More than an upgrade — a transformation

CTE Carbon Ceramic brake discs are crafted from next-generation Carbon Fibre Reinforced Ceramic (CFRC). Developed through years of intensive R&D for major European OEM manufacturers, our proprietary process transforms Carbon/Carbon (C/C) into Carbon/Silicon Carbide (C/SiC) — the same material class deployed in aerospace turbine components and Formula-class racing. If you have piloted a European Hypercar or a track-ready Porsche equipped with upgraded ceramics, you have likely already experienced the precision and quality of CTE.

The CTE advantage: continuous long-fiber technology

While most factory-standard carbon ceramic discs — such as the Brembo / SGL CCM — utilise T300-grade discontinuous (chopped) fibers, CTE utilises T700-grade continuous (long) fibers woven into a patented 3D matrix architecture. This distinction is fundamental: continuous fibers carry load along their full length, eliminating the micro-crack propagation pathways that limit chopped-fiber composites under repeated thermal cycling and mechanical stress.

Feature Standard OEM Discs (CCM) CTE 3D Matrix (C/SiC)
Fiber Grade T300 discontinuous (chopped) T700 continuous (long fiber)
Fiber Architecture 2D random mat 3D needle-punched matrix
Matrix Carbon/Carbon (C/C) or basic C/SiC Proprietary C/SiC via LSI at 1500°C
Surface Hardness ~1500–2000 HV >2800 HV
Weight vs Cast Iron ~40% reduction ~50% reduction
Thermal Fade Possible above 800°C Zero fade to 1000°C+
OEM Qualification Standard OEM supply European hypercar OEM qualified

Frequently asked questions

What is the difference between CTE C/SiC and standard OEM carbon ceramic brakes?
Standard OEM discs use T300-grade discontinuous (chopped) carbon fibers in a 2D random architecture. CTE uses T700-grade continuous long fibers in a patented 3D needle-punched matrix, producing higher tensile strength, superior delamination resistance, and stable friction performance from cold start to beyond 1000°C.
What is the maximum operating temperature of CTE carbon ceramic brake discs?
CTE C/SiC discs maintain stable friction performance at temperatures exceeding 1000°C with zero thermal fade. The Silicon Carbide matrix — formed during Liquid Silicon Infiltration at 1500°C — provides exceptional thermal stability far beyond cast iron or standard composite discs.
How much lighter are CTE carbon ceramic discs vs cast iron?
CTE C/SiC discs deliver approximately 50% weight reduction versus cast iron equivalents. Reducing unsprung rotating mass directly improves steering response, ride quality, and overall braking system efficiency — particularly beneficial in motorsport and high-performance road use.
Which vehicles are CTE carbon ceramic brakes compatible with?
CTE supplies C/SiC brake discs for European hypercars, high-performance GT and sports cars, and track-day vehicles including Porsche models with upgraded ceramic brake systems. CTE technology has been qualified under major European OEM manufacturer programmes.
CTE Carbon Composites — Aerospace Engineering, Track Proven