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BRAKE DIsc for AutoMotive - performance enhancement by insertion of diamond particles

Periodic Reporting for period 1 - BrakeDiam (BRAKE DIsc for AutoMotive - performance enhancement by insertion of diamond particles)

Reporting period: 2015-11-01 to 2016-02-29

Ferdiam is a company that spinned-off from DELLAS S.P.A. to approach new commercial and industrial uses of the industrial diamonds. Enlarging current portfolio of art-decoration purposes, the BRAKEDIAM project focuses on the Automotive market, specifically in the braking systems manufacturers and assemblers.

The BRAKEDIAM project aims to develop an innovative Disc Brake for cars and motorbikes that integrates industrial diamond powder along the braking surface of the disc. The benefits of this product are: Better heat dissipation due to the exceptional thermal capabilities of diamonds (thus increasing life cycle of the disk); Better features in terms of vehicle-stopping time; Reduced emissions of breathable PM10 particles, linked to each braking event at any braking system.

In order to confirm the viability of our project, a feasibility study have been conducted by our team from November 2015 to February 2016. Technically, we have further developed and assessed the different features of the technology, including the iterative process of validating the model and how it makes hit and response to the European market of Automotive manufacturers. Commercially, we have consolidated our knowledge of the automotive market and developed a strong marketing strategy, taking advantage of our expertise and industrial experiences in handling and manufacturing with industrial diamonds. Also included is a freedom to operate study, risk analysis, financial forecasting and planning through full-scale production.
Phase 1 Proposal was granted (Score 14.49/15 points) and included a specific introduction to the forecasted Work Package that comprises several activities that we have carried out in our 4-month feasibility study.

Technically, additional designs and tests with motorbike brakes were carried out in November, January and February following our agile development plan, to further assess 1/brake performance, 2/limits and tolerance and 3/optimum friction coefficient. All these tests provided positive results, confirming the technology and its adaptation from motorbike to car brake discs.

Following these developments, a preliminary risk analysis has been conducted to ensure that no issues have been left aside and thus that future developments will be with a low and controlled risk. Our team has prepared a preliminary Execution Plan for the development and exploitation and the BrakeDiam range; we also assessed the need for third party subcontractors to support us in the execution of the Phase 2 project.

Commercially, we have focused on the potential markets and market niches (cars, racing cars, motorbikes, trucks); this has allowed us to further prepare our marketing and pricing strategy. Furthermore, a complete Freedom-to-Operate was performed to search for existing Intellectual Property rights that could infringe with our technology. This analysis has confirmed the novelty of BrakeDiam and the absence of existing thread for its commercialization.

Financially, scenarios have been analysed and detailed, leading to consolidated financial projections for the 2018-2022 period with highly positive turnover increase and Return on Investment > 1.5.
By launching BrakeDiam, an innovative braking system using disc brakes made of a composite material with diamond particles, we, Ferdiam, will address the need from the automotive industry for safer, lighter, higher performance and cost-effective solutions. In particular: up to +15% in friction performance, -50% reduction in PM10 particles emissions, +40% in durability.