Breaking boundaries with the Bugatti Bolide – Bugatti Newsroom

From initial data to dyno testing to track analysis, Brembo racing engineers worked in close collaboration with Bugatti to tackle the challenges associated with creating a braking system that is truly unique in its design and level of performance. The result, following two years of demanding testing and development, is a carbon-carbon system that matches the technology that goes into LMh/LMDh and Formula 1 machines.

The stopping power produced by the Bolide is in a class of its own. Its standard front brakes are the largest carbon-carbon brakes ever, featuring two eight-piston calipers, both with four high-performance 25mm pads, and 390×37.5mm carbon discs. The calipers themselves are made of aluminum alloy and nickel plated.

At the rear, two six-piston calipers mirror the front with four high-performance pads, albeit slightly narrower at 24.5 mm. Completing the rear calipers are 390×34 mm carbon discs. Although not as large as their front counterparts, the dimensions of the rear braking system are in line with the LMDh racing class, exemplifying Bugatti’s steadfast commitment to delivering unrivaled track performance.

“Developing the braking system for the Bugatti Bolide was a unique and very exciting challenge for the Brembo Performance Division – and we are proud of what we achieved” said Mario Almondo, Chief Operating Officer of Brembo Performance. “We had to rework the whole system to deal with the car’s incredible but demanding characteristics, for example, it’s a masterpiece of engineering in my view, if it’s the biggest we’ve ever put on a racing car. Using carbon compounds similar to those those in Formula 1 meant that, despite the Bolide’s size and power, we were able to deliver the lightest possible design.

This option first of all allowed the engineering team to significantly reduce the overall weight of the system – each disc on the Bolide weighs only 3,175 kg. But it also ensured the brake system would provide exceptional thermal conductivity for superior heat dissipation during extreme braking conditions, preventing brake fade and ultimately providing Bolide owners with consistent performance even under adverse conditions.

Bolide’s braking system isn’t just about calipers, pads and discs, however; it is a balanced combination of engineering precision. A holistic approach ensured that every part works as one. This includes bespoke master cylinders and specially designed fluids that further enhance the Bolide’s dynamics.

In creating a high-performance sports car that draws inspiration from the pinnacle of motorsport, the ability to consistently deliver exceptional performance in all track conditions is paramount. In line with this ambition, Brembo engineers played a key role in the sculpting of the Bolide’s brake air ducts, collaborating with Bugatti to precisely adjust the air flow to the needs of its modern braking system.

Bugatti’s collaboration with Brembo greatly improved the brake cooling system. This strategic development was important, considering the energy and torque produced by the Bugatti W16, especially towards the front wheels, during intense track sessions. In handling this, 85-90% of the air flow is directed to the discs and pads, and a small part reaches the calipers.

Since the inaugural computational fluid dynamics (CFD) sessions for the Bolide project in 2022, the team embarked on a journey to develop and test the braking system, ensuring it can withstand the Bolide’s exhilarating speed on track. Over the course of two years, data collected from simulations, dynamite sessions, and detailed analysis performed on race tracks was fed back to Brembo engineers.

More commonly, the assessment examined potential abuse situations where tension management frequently intervenes. It involved extensive testing of the Bolide’s ‘Wet’ mode, designed to prepare the track-only sports car for the use of wet tires in difficult driving conditions. This driving profile makes fine adjustments to the control system, increases the ability to adapt to slippery surfaces by influencing the ground, and activates a unique rain light reminiscent of the red lights seen in Formula 1.

This feedback not only allowed the project team to fine-tune the performance of the braking system but also ensure that the Bolide stands up unchallenged in every aspect – thriving in a variety of weather conditions without compromising safety or security.