CFD simulations, laboratory endurance testing, and real-world validation — SwissStop applied all three before finalizing the Catalyst Pro rotor design. The engineering team created digital prototypes to test sculpted brake track patterns, then verified that simulation data matched actual performance on their in-house dynamometer. That development process produced a two-piece rotor that delivers consistent brake torque over extended use while competitors experience gradual decline and eventual fade.

The two-piece construction pairs a SUS410 stainless steel brake track with a 7075-T6 aluminum spider. Stainless handles the thermal demands of the braking surface while aluminum reduces rotating mass and improves heat dissipation through the center section. Steel rivets join the two pieces, and the spider's shape contributes to overall stiffness while creating airflow paths that pull heat away from the brake track. SwissStop's testing showed that adding selective material to the outer ring — accepting a few extra grams — translated directly into shorter stopping distances and improved durability over featherweight alternatives.

The Catalyst Pro addresses noise through brake track geometry that minimizes pad vibration at the contact area. Riders report notably quiet operation, particularly when paired with SwissStop's EXOTherm2 or Disc RS pads, though the rotors work with any sintered or organic compound. Three small divots per side serve as wear indicators, showing when replacement becomes necessary. The perimeter edge contains no 90-degree angles — a UCI requirement for road competition that the 140mm and 160mm sizes meet.... Read More