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The European Union is tackling a hidden source of pollution: particulate matter from car brakes. With the Euro 7 standard, set to take effect by 2026, the focus shifts from exhaust emissions to brakes and tires. These tiny particles, created when brakes wear down, harm air quality and public health. The EU Environment Agency estimates that 250,000 Europeans die prematurely each year due to excessive pollution. Now, carmakers must cut brake wear by 80% to keep selling in Europe.
Key Highlights:
- The Euro 7 standard targets particulate matter from brakes.
- TRUMPF Laser and Nagel created a laser coating solution.
- Coated brake disks are tougher and wear less.
- Electric cars benefit from rust-free brakes.
TRUMPF Laser and Nagel have teamed up to address this challenge with a new technology. They use a high-speed laser process to coat brake discs with a super-hard layer of carbide. This makes the discs ten times harder than typical cast iron ones, reducing wear and dust. The process has two steps: first, the laser applies the coating, leaving a rough surface. Then, a grinding machine with diamond tools smooths it out, creating a nearly abrasion-free disc.
This innovation shines for electric cars too. These vehicles often brake using energy recovery, leaving mechanical brakes unused and prone to rust. Rusty brakes can fail in emergencies, lengthening stopping distances. The laser-coated discs resist corrosion, boosting safety for electric car drivers.
Developing this wasn’t easy. Cast iron is tricky to coat—layers don’t stick well. TRUMPF’s BrightLine Weld technology shapes the laser beam to use powder efficiently, cutting waste and costs. Tests are underway, and cars with these disks could hit roads by late 2025. Beyond compliance, this tech could lower pollution and save lives, as Nagel’s Lott says: “Less particulate matter means healthier people.”
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