2025
Brake-by-wire
Selecting a partner that is experienced, agile and that has advanced capabilities is key.
Datwyler’s own core competencies of focus are material expertise, solution design and operational excellence – and outlined below is how those competencies add tangible value to braking systems projects.
Advanced material development
Braking systems require the safest, most reliable materials in order to deliver the best performance. The EHB, for example, presents challenges that must be addressed right from the material development stage. The cleanliness of the compound means there must be very low residual dirt, whilst the highest requirements must be met for elements such as precision molding and low tolerances.
At Datwyler we control the process in-house, from raw materials testing and research and elastomer compound formulation, to materials science and mixing via our own mixing facilities. We are especially proud of our brand-new, state-of-the-art mixing facility in Nový Bydžov, Czech Republic. We also control the production process set-up, and via our dedicated Technology and Innovation Labs can develop surface treatments, ensure chemical compliance and carry out failure analysis and quality control.
Datwyler’s materials and surface technologies support
Best-in-Class Simulation
Solution design is a core element in producing system-critical components for braking systems. Here we have the capabilities in structural mechanical analysis to deliver best-in-class solutions. Using Finite Element Analysis (FEA) to develop solutions together with our customers, the development process can be accelerated, enabling them to deliver systems that provide the highest levels of functionality. Parameters are set for the specific application, from which a first design is produced, tested and optimized purely in the virtual space. This provides a functional design, ready for prototyping, that should pass the endurance test of our customers.
These designs are as close as possible to the serial design, from which process efficiency and product quality can be effectively managed via virtual molding to simulate all of our manufacturing processes. Testing and modeling follow, and the value and the reliability of our simulations are dependent on accurate material models. Datwyler’s testing and modeling capabilities are best-in-class because we can ensure the highest accuracy as our materials are developed 100% in-house.
Datwyler’s simulation capabilities for each core competency
Structural Mechanical Analysis
Solution Design
Virtual Moulding
Operational Excellence
Testing & Modelling
Material Expertise
Worldwide manufacturing excellence
Ensuring quality and consistency of manufacturing is vital. At Datwyler we have the global reach and expertise to take virtual processes into real-time production wherever our customers need our support. We are able to take a project from the identification of a challenge, through the ideation phase to material and design proposal, testing and modeling, component drawings and tool manufacture and finally, via flow simulation, into full scale production.
Our expertise has led to cost reductions of up to 30% in terms of parts we have designed and optimized based on customer’s original designs, which have all been produced through Datwyler’s Production System (DPS). This global approach fosters a lean culture dedicated to operational excellence and zero defects. In addition, given the requirements of EHB technology, at the company’s Schattdorf base in Switzerland there is also a clean room operation to fulfil the highest cleanliness requirements in the automotive industry.
Lean and Clean production in Schattdorf, Switzerland
Here for the past, present and future
Of course there is a transitional phase that will eventually see brake-by-wire technology entering the mainstream equation, and we have already begun this path (read our blog on BBW technology). What we must not forget, however, is that legacy technology is still very much in use today, as well as the current innovation of EHB. Datwyler is synonymous with braking systems, and has made a commitment to continue to serve our customers and to be ‘the last man standing’ across all brake technologies as some players move away from areas such as the vacuum booster.
Brake-by-wire: enhanced stopping power.
Daniel Triolo, Lead Key Account Manager at Datwyler, looks at brake-by-wire technology, its composition, and the many benefits it can deliver to the mobility sector and its customers.
Brake-by-wire
Electric parking brake
Electrohydraulic booster
Vacuum booster
Some Datwyler product examples for relevant applications in brake systems
Mobility 
Brake-by-wire 
Brake Systems 
Electrification 
Material expertise 
Solution Design