Brake Duct

This project focused on developing Staffordshire Uni Racing’s first full brake cooling solution, including a 3D-printed brake duct and shroud assembly. The goal was to channel airflow efficiently to the discs, reduce brake fade during endurance runs, and create a durable, lightweight package that integrated seamlessly with the uprights.

I began with CAD concepts and multiple prototypes, testing airflow direction and fit. The shroud was also designed to mount securely while resisting heat and vibration. Both components were manufactured in Onyx (carbon-fibre reinforced nylon), chosen for its strength-to-weight ratio and thermal resistance.

The final assembly significantly improved brake temperature control under race conditions and was featured in Racecar Engineering magazine as an example of innovative Formula Student engineering.