In Formula 1, every detail contributes to a car’s overall performance, and few systems are as stressed as the braking system. Brakes endure extreme thermal and mechanical loads, and while aerodynamics and power units often dominate media attention, managing brake temperatures remains crucial for performance, reliability, and safety. Brembo has long been a technical benchmark for the grid, particularly in brake ventilation and the design of cooling holes in carbon discs, one of the most complex and least visible aspects of F1 engineering.
Why brake ventilation is crucial
During heavy braking, carbon discs can reach temperatures above 1,000°C, especially on circuits with strong deceleration zones and low-speed corners. Without adequate cooling, these temperatures can cause performance drops and reliability issues.
The main risk is brake fade, a loss of braking efficiency caused by overheating the friction materials. Additional problems include brake fluid boiling and reduced pedal sensitivity, which compromise a driver’s ability to modulate braking.
However, undercooling is also an issue. If brakes operate below their optimal range, roughly starting around 350°C, the friction coefficient drops, and the system cannot deliver its full potential. In Formula 1, the goal isn’t simply to cool the brakes, but to maintain them within a very narrow temperature window throughout every phase of a race.
The ventilation holes: more than just openings
Engineering solutions come in the form of internal ventilation channels in the discs, designed to guide cooling air through the disc structure. Air from the brake ducts passes through these channels, extracting heat from the most stressed areas.
Designing these holes is delicate work. It’s not about increasing the number of openings, but optimizing their geometry, orientation, and distribution to ensure effective cooling, uniform temperature distribution, and reduced thermal stress within the material.
Brembo extensively uses CFD (Computational Fluid Dynamics) simulations to analyze airflow within the disc and fine-tune every design detail before production.
Evolution over time
The evolution of F1 brake discs reflects the increasing performance of the cars. About twenty years ago, carbon discs had roughly 70 ventilation holes—a number that today would be unthinkable.
As speeds, aerodynamic loads, and braking energy increased, the number of holes grew quickly. In the early 2000s, discs evolved to several hundred holes, reaching more than 1,400 in extreme configurations for demanding circuits, spread across seven rows.
These extreme solutions, used before recent regulation changes, aimed to maximize airflow and thermal dissipation without compromising structural strength.
The impact of technical regulations
In F1, technical evolution is closely tied to regulations. Since 2022, a minimum hole diameter of 3 mm has limited the maximum number of ventilation channels. This reduced past extremes but did not diminish the complexity of the work. Today, front discs typically have between 1,000 and 1,100 holes, varying by circuit and team requirements.
Previously, teams could choose between:
- Medium cooling discs, with about 800 holes;
- High cooling solutions, with over 1,200 holes;
- Very high cooling versions, reserved for the most demanding tracks.
With the introduction of 18-inch wheels and new aerodynamic management around the wheels, integration between brakes, ducts, and bodywork has become even more sophisticated.
A delicate balance
An effective ventilation system cannot focus solely on maximum heat dissipation. Overcooling can push brakes out of their ideal window, reducing grip and consistency. Poor hole distribution can cause localized stress, uneven wear, and the risk of cracks or failures.
All of this must be integrated into the wheel corner, a highly complex area containing brakes, suspension, wheels, and aerodynamic components. Every design choice for the brake disc has repercussions far beyond the braking system itself.
Ventilation as a performance factor
In competitive Formula 1 racing, brake ventilation is not just about reliability; it’s a genuine performance lever. A system operating within the correct thermal window allows drivers to brake later, with greater consistency and better pedal feel.
The design of ventilation holes in F1 brake discs is thus a complex balance of thermal, mechanical, and aerodynamic considerations. It’s a precise, often invisible task, but fundamental in allowing F1 cars to fully exploit their potential on the track.
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