Development of Composite from Waste Materials for the Manufacturing of Automotive Brake Pads

Abstract

Asbestos-based brake pads pose health and environmental risks, while
conventional alternatives are costly. This study aimed to develop an
eco-friendly, cost-effective brake pad using locally available waste
materials: sawdust, coconut shells, and ceramic clay. The materials
were cleaned, ground into fine powders, and mixed with polyester
resin, benzoyl peroxide, and MEKP in varying ratios to form three
composite batches (A, B, C). Samples were molded under 6 MPa at
wear resistance, and water absorption, and compared with a
commercial brake pad. Results showed densities of 2,414
hardness values of 94.16 97.66 HD, and wear resistance comparable
to commercial pads, with Batch C performing best. Water absorption
(0.001474 0.000986kg) was higher due to the organic content but did
not compromise mechanical performance. The study demonstrates
that combining organic and inorganic waste can produce strong,
durable, and environmentally safe brake pads. This approach offers a
sustainable, affordable alternative for automotive applications, turning
local waste into valuable engineering materials.