It was in this environment that the Head of the Machining Workshop decided to push the limits of his creativity and the company's capacity for innovation.
This was the same man who, just a few years earlier, despite the limited resources available at the time, had succeeded in applying billet machining to produce two-piece calipers supplied to F1 teams. He went to the engineers and presented them with a new challenge: to design a monoblock caliper — a solution considered inconceivable at the time due to the enormous production difficulties.
The Birth
The engineering team was well aware of the advantages of a caliper made from a single block of metal: compared to a two-piece caliper joined by bolts, this type would offer greater rigidity and reduced weight. At the same time, it would not suffer from the issues caused by the different thermal expansion of the aluminum in two-piece calipers and the steel of the fastening bolts. It was a fascinating solution that promised exceptional braking performance, but it was considered unfeasible: machining the inside of a caliper with the tools available at the time was a near-impossible challenge.
With many doubts and a few secret hopes, the team began working on both the product and the process, accepting the challenge and designing the first monoblock caliper. The task was arduous, but once again the perseverance of those involved ensured that the first monoblock caliper finally emerged in 1987. And already the following year, it made its debut in Formula 1. A result that gave Brembo a significant competitive advantage over its rivals.
From Formula 1 to road-going supercars, the step is relatively short. Less than a decade later, monobloc technology debuted on the Porsche Boxster. From there, a journey began that would lead Brembo monobloc calipers to equip almost all high-performance road cars in the following years.
But not only that: this technology has become so synonymous with Brembo that it is now available to the most passionate consumers through Brembo’s Upgrade offering, which represents Brembo’s exclusive world and provides enthusiasts with performance, style, and passion. The exceptional results Brembo achieved on the world’s most important racing circuits led directly to braking system upgrades for enthusiasts, allowing them to improve the style, performance, and reliability of their vehicles — whether used on the road or in time trials on the track.
However, the spread of the monoblock caliper concept didn’t stop with cars. In just a few years, it also reached the world of two-wheelers, even though there was still a long road ahead before this technology could transition from Formula 1 to the Motorcycle World Championship. The smaller size of motorcycle calipers compared to those used in Formula 1 made machining the inside of the caliper even more complicated.
The main challenge was producing a tool small enough to enter the "pocket" (the housing for the two brake pads) of the caliper and still be able to machine the piston bores. It took years of study and testing to overcome this obstacle — not to mention the use of special solutions inspired by the world of watchmaking.
After much hard work, Brembo finally succeeded in developing the first monoblock brake caliper for motorcycles toward the end of 1992 — once again ahead of everyone else. The first track tests were carried out with Wayne Rainey’s and Luca Cadalora’s Yamaha 500 at Phillip Island during private testing in January 1993. These continued during the winter pre-season tests with various teams. At the season opener in Eastern Creek, Australia, on March 28, 1993, the first to use the monobloc caliper in a race were Mick Doohan and Daryl Beattie's Hondas, along with Doug Chandler’s Cagiva. Yamaha waited until the third race, in Suzuka, before adopting them permanently.
The first race win came three races later, at the German Grand Prix in Hockenheim, where Daryl Beattie won the first motorcycle race with a monobloc caliper. And with that first victory, motorcycles also began their journey to bring winning performance to the road: it took 13 years, but in 2006 came the first original equipment application.
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Whether it’s Formula 1, MotoGP, or any other racing environment, in its 50-year history, Brembo has designed and tested new materials, technologies, products, and solutions that eventually find their way into road applications.
Brembo’s monoblock calipers are an example of the highest level of performance that a caliper can achieve: a simple example from a two-decade-long saga that helps tell the story of Brembo’s relentless innovation.
The story of the monoblock caliper’s development is a testament to the company’s innovative spirit and perseverance. This technological breakthrough not only revolutionized braking performance in racing but also paved the way for new road applications, demonstrating how a passion for innovation can lead to extraordinary results.
Brembo continues to be a leader in the sector, constantly pushing the boundaries of technology and improving vehicle safety and performance on both road and track. Its dedication to research and development is an example of how innovation and creativity can turn bold ideas into tangible realities, benefiting millions of people around the world.