The design of a prototype, its realization and testing is a crucial step in the InterCar production process, as it allows to verify the real compliance of the brake disc with the initial specifications, before its mass production. In detail, structural, modal, dynamic, thermal, fluid and Finite Element Method analyzes are carried out on the prototypes and, also, stress tests and simulations.

During the Design Engineering process, InterCar constantly pursues the principles of extensive and scientific calculation of every constructive and functional aspect, through a generalized use of the concept of variation in geometric progression, in order to study and search for perfection in every detail in technical, technological and economic terms, in full compliance with the reference regulations.


InterCar, in line with its long path aimed at continuous improvement, has equipped itself with a dynamometer to simulate the braking of any vehicle, or rather of a wheel, in any load condition and to analyze all the parameters that characterize the behavior of the product, in its possible applications.

Operating 24 hours a day, the dynamometer is also used for the approval of discs according to the ECE R90 standard. Finally, attention to the quality has always characterized every business’ choice, which has implemented a systematic and rigorous control on production processes, materials and finished products, in order to achieve important results, also in terms of productivity.



The introduction of flexible processing systems and their grouping by phases, together with an integrated order and warehouse management ensure a very low customer lead time, testifying to InterCar’s ability to be prompt and efficient in satisfying its customers.

The Lean methodology, introduced in the Company since several years and rigorously applied to the production phase, has fully become part of its culture. It has been implemented in order to avoid waste, minimize stocks and optimize efficiency and productivity. This method had very positive repercussions even in the initial design phase, reducing its development times, always respecting the required performance, and, therefore, the cost-effectiveness of the entire project.

This multifunctional and structured development’s approach is progressively leading the Company towards a careful reduction and removal of useless phases and activities of the production process and of all those elements which, in the fulfillment of an order, are not relevant neither for the customer, nor for the Company business.


The combination of technologically advanced production machinery and an automatic transport system for feeding and picking up from the island processing centers allows the entire process to be optimized: from the processing of raw material to the coating, up to the packaging of finished products.

The company offers three types of coating: anti-corrosion Alutherm® with low environmental impact, for the After Market, UV and Zinc Dust for the first assembly, which affect the entire range of brake discs, applied by a robot able to adapt itself to different sizes of the piece, even within the same line.

A fully automated department designed to meet the ever growing demand for painted discs, ready for assembly, to guarantee excellent aesthetic impact and protected disc surfaces, without compromising braking performance.


All production is subjected to a Statistic Process Control, using electronic equipment that examines the raw material and samples of pieces during the various stages of processing.

The systematic nature and extension of the controls allow to produce quality, rather than obtaining it only by selection, improving the overall productivity of the company.