this 3D floating rotor addresses overheating + deformation in bicycle braking systems

3D Floating Rotor by PSB bike 

Equipping bikes with a solid braking system guarantees a safe and smooth riding experience. However, using hydraulic disc brakes as the new standard in cycling has hindered that expectation by causing a flare-up of issues. In light of that, Taiwanese company PSB Bike has released the Two-Piece 3D Floating Rotor — an innovative long-term solution to tackle the menacing unpredictability of current braking systems.

addressing overheating and rotor deformation 

Overheating and rotor deformation are two problems caused by hydraulic disks that riders cannot control. Most of the rotors on the market warp at different degrees during constant braking, and many don’t spring back to a flat state after cooling. In addition to safety concerns, the current disc system rubs against the brake pad, creating abnormal noises. The 3D Floating Rotor, therefore, hopes to address these issues. 

PSB Bike (see more here) explains it further: ‘When the hydraulic liquid is sent from the brake lever toward the caliper to push the pistons, it is difficult to ensure that the caliper will maintain an even amount of push out after long-term use. When the caliper moves, the uneven pushout of the pistons will bend the rotor directly. Obviously, the common issue here is the rotor’s deformation, which is also why a floating rotor is indispensable.’

designing a rotor with floating and elastic properties 

The proposed rotor design stands out from other models thanks to its elastic and floating outer disc. The floating function is enabled through spring rivets on the back of the rotor, creating insulation between the outer and inner discs. Meanwhile, open cuts on the 6th and 12th ribs provide the rotor with its elastic property — making it deformable both horizontally and vertically.

The unique angle cuts offer support when margin space reaches the set value along the direction of force when braking. In other words, the open cuts do not affect disc strength. These features help the disc move and deform at a distance that is 85% larger than conventional floating rotors. The structure also puts the strength of this 1.8-millimeter thick rotor on par with other 2.0 millimeter thick rotors.

With all these features set in place, the 3D Floating Rotor can effectively prevent any potential brake fade and rotor deformation caused by heat, offering riders safety and assurance while braking. The proposed design also eliminates the uneven caliper clamping, ensuring air-tight braking performance and prolonging the service life of both rotor and brake pads. Frame resonance noise is also reduced.

PSB Bike’s design can also satisfy the braking forces of electric bicycles, making it a one-size-fits-all solution on the market. As a result, the 3D Floating Rotor has won the Red Dot Product Design Award & 2022 iF Design Award. 

project info:

name: Two-Piece 3D Floating Rotor
design: PSB Bike

designboom has received this project from our DIY submissions feature, where we welcome our readers to submit their own work for publication. see more project submissions from our readers here.

edited by: lea zeitoun | designboom