Rotor tech talk

The search for the best disc-rotor design started in spring 2017. After some designs which didn't work well I found a way to combine all positive aspects I wanted to sum up in one design, which are:

  • high power
  • low temperature
  • less wear of your pads
  • a smooth braking modulation
  • nice design
  • low and high weight in one design

The Intend Aero rotors are manufactured by BrakeSTUFF /, a company with a very long history and experience with the manufacturing of rotors. They stand for made in germany, small numbers and manufacture-like production. That is the perfect supplier for the Intend Aero rotors!


High power: this depends on the correct material and a big contact surface to the brake pad. BrakeSTUFF deliveres best materials and surface quality!


Low temperature: This is probably the most interesting thing about the Aero discs. 

It is not possible to avoid upcoming heat at a brake. That's physics. But you can do 3 things:


1. The contact area of the brake pad and the rotor has to be as big as possible. Otherwise the pressure will increase and this would result in an higher spotty temperature. 


2. The braking energy should result in a low temperature. This can be achieved with a big mass of the outer ring. The reason is the heat-capacity, which is Q = c * m * T. The higher the mass, the lower the temperature.


3. the braking heat should be blown away as fast as possile. It is not possible to prevent a upcoming heat of the system, but you can try to blow it away as fast as possible. The magic here is called "surface". The more outer surface, the better the heat can be blown away.


But how can point 3 be achieved without loosing point 1 ? 

Answer: The smaller the holes, the smaller is the loss of side surface while the overall surface rises - this is very easy, no one does it before. The simplest geometric fact, now done with the Intend Aero rotors.


Traditional rotors have a surface like shown left, the Aero rotor on the right.


                                           Overall surface of the outer ring

Surface calculation of standard rotor:



203mm with 13,5mm outer ring height: 8037mm²


Surface of holes (each): 

Circumference of 5mm diameter * disc thickness(1,8mm) minus side-surface: -11mm² 


Outer surface of the disc:

Circumference of 203mm*thickness (1,8mm): 1148mm²



2 x 8037mm²  + 108 x (-)11mm² + 1x 1148mm² =


16034 mm²



Surface calculation of Intend Aero rotor:



203mm with 13,5mm outer ring height: 8037mm²


Surface of holes (each):

Circumference of 1,9mm diameter * disc thickness(2,25mm) minus side-surface: +7,8mm² 


Outer surface of the disc:

Circumference of 203mm*thickness (2,25mm): 1435mm²



2 x 8037mm²  + 698 x (+)7,8mm² + 1x 1435mm² =


22925 mm²


This is an increase of 43% to the left rotor!

Temperature measurements:


Measurements with a XY "floating" rotor compared to Intend Aero rotors showed up the following results.


The test-trail is the Canadian trail in Freiburg which has 400hm with small climbes in between not too deep descends. The time of one run is about 15 min. 


The green line shows the temperature of the XY rotor. As you can see clearly, it rises much faster than the same sized Intend Aero rotor.

The measurement is done for each rotor size with the following circumstances:


- same day for a ride with same sized rotors

- measurepoint was the inside of the outer ring, both with 14mm distance from outer diameter

- same bike, same rider, same riding condition

- 180mm measurement was incl. Stage 1

- 203mm measurement was excl Stage 1, thats why this diagram is shorter.








As you can see clearly in the diagrams, the Intend Aero rotors overall has about 20-30 % less heat in the disc than the XY rotor. the 203mm rotors had exactly the same weight, the 180mm rotors has 163g (Intend 180mm 2,25) and 155g (XY Rotor)


Wear of the brake pads:

The holes in the disc rotor are one reason for the fast wear of the brake pads. The bigger the holes, the faster the wear.


Why? This is why:


It is a widespreaded belief that thicker discs grinds more at the pads comparedto thinnner discs.




the free stroke of the pads to the discs are always the same, doesn't matter if you have used pads, thicker or thinner discs. the free stroke is part of the brake system and does NOT change with pad wear or what ever.


So you can use 2,25mm discs also in your Shimano brake, Trickstuff brake, Avid ..... without any problems!