Brake calipers are usually manufactured by casting, but die casting is not the most common process method. The manufacturing process of brake calipers mainly includes sand casting, precision casting or gravity casting.
Sand casting is one of the most common processes and is usually used to manufacture large-sized and complex-structured castings. Sand casting can produce more complex shapes and higher strength requirements. Brake calipers are cast using aluminum alloys or iron alloys, and sand casting can provide sufficient strength and wear resistance.
For some brake calipers that require higher precision and surface quality, precision casting may be used. This process can achieve higher dimensional accuracy and better surface finish.
Gravity casting is for larger castings, molten metal is injected into the mold under the action of gravity, which is suitable for manufacturing larger and more complex brake calipers.
Nevertheless, some high-end brake calipers may use aluminum alloy die-casting, especially in some lightweight designs, but this is usually when the strength requirements are not so strict or it is widely used in light vehicles.