Precision Disc Brake Design & Production

Driven by a desire to innovate and exceed expectations, the Hayes engineering team is proud to have a breadth of competencies, experiences, and capabilities that are unique within the industry.

Hayes Team

A Legacy of Innovation, Built to Perform

Unparalleled Experience

Knowledge and wisdom are on our side. Our engineers average 15 years of experience, and each team member has brought to Hayes—or developed from within—brake-specific expertise and application know-how.

What’s more, our engineers are immersed in the markets we serve, living and breathing them even outside of work hours. Many are avid riders, drivers, or racers, and all have a passion for ensuring we make the best products in the business.

Nurturing Our Future

We’re always on the lookout for brilliant minds. Our internship program ensures that talent is identified, nurtured, promoted, and retained. It’s been so successful that past interns from this program now represent roles in engineering, sales, product management, and leadership.

The Hayes team also boasts certified Six Sigma Green Belts, leadership, and program management curriculum graduates, plus several team members who are active in professional consortia.

A Collaborative Mindset

Our success comes from respect and collaboration. We recognize and appreciate the knowledge and experience of others, and we work tirelessly with one another—regardless of department—while working with customers to develop the right solutions the right way.

Hayes Bicycle

A Proven Method for Disc Brake Design & Manufacturing

Our Process

Engineering & Testing

Hayes employs top-tier engineering methods and test procedures aimed at ensuring quality, consistency, transparency, and quick issue resolution. Our Research & Development (R&D) process is tailored to support a fast pace, leading to the learning cycle mantra above.

Our sophisticated tools include:

  • 3D modeling, multi-physics analysis, and vibration analysis software
  • Fully staffed lab with state-of-the-art laboratory management system
  • Workflow management tied directly to departmental performance metrics
  • Key equipment with monitoring and control to allow 24/7 test support and preventative maintenance
  • Vehicle proving ground for on-road and off-road applications
  • Methods to support bicycles, wheel loaders, and everything in between

Meeting exacting specs is one of the Hayes engineering team’s biggest motivators—whether it’s from government vehicle applications, high-performance race vehicles, or anything in between. And speaking of races, the Hayes R&D team actually uses the racing environment to test products under rigorous demands.

Engineers at Hayes have the exciting and enviable opportunity to directly interact with customers and competitive athletes in multiple racing disciplines. In some cases, Hayes engineers are embedded on professional race team crews, while others are able to attend events and address questions from race crews and get direct feedback on the product. This valuable input makes its way back to the development team for any necessary product improvements or new opportunities.

Hayes R&D currently partners with teams that participate in:

  • MotoAmerica, Superbike Class
  • Bagger Racing League
  • Championship Snocross
  • Short Course UTV Racing
  • Cross-Country Snowmobile
Road America

It starts with the right people.

Hayes partners with world-famous Road America near Elkhart Lake, Wisconsin for the purpose of on-road and off-road testing of vehicles. We operate there from our private test garage, which is a short 45-minute drive from our engineering headquarters in Mequon, Wisconsin.

While most lab testing is completed at our engineering headquarters, we maintain multi-year key partnerships with local and regional specialized test labs to ensure we have capacities and capabilities at any time to test products.

Analytical Engineering Tools

We use advanced digital tools to design, validate, and refine brake systems before physical testing begins. These methods ensure accuracy, efficiency, and performance from concept through production.

  • CAD and basic FEA stress and deflection using PTC Creo
  • Advanced FEA (multi-physics, non-linear, fatigue) using ANSYS
  • Standardized predictive tools for brake system sizing, bolted joints, tolerance stacks
  • Product Data Management using PTC Windchill platform 
(PDMLink) – configuration management for both R&D and production environments
  • ReliaSoft XFMEA software
  • Clarivate Derwent Innovation patent search software

Vehicle & Real-World Testing

We validate brake performance through on-road and off-road vehicle testing, combining real-world conditions with advanced data acquisition to confirm durability, safety, and system behavior.

  • Fleet of 15+ vehicles, Hayes and customer-owned, covering a wide range of markets
    Hayes partners with world-famous Road America near Elkhart Lake, Wisconsin for the purpose of on-road and off-road testing of vehicles. We operate there from our private test garage, which is a short 45-minute drive from our engineering headquarters in Mequon, Wisconsin.
  • VBOX, 2D, and ETAS vehicle data acquisition systems, including CAN bus interfaces, analog input, analog outputs, and digital data outputs, with sampling rates of up 1000 kHz to cover any needs for vehicle testing and characterization.

Physical Testing & Validation

Our in-house labs and real-world testing environments allow us to validate brake performance under demanding conditions. From component-level testing to full-vehicle validation, we verify durability, safety, and reliability.

  • Custom 100 hp brake dynamometer with ProLINK controls, up to 1850 ft-lbs, 235 mph 2000 RPM, 50 slug-ft² ANSI/ROHVA, SAE, FMVSS simulations, and customized scripts available
  • Fleet of 20+ vehicles, Hayes and customer-owned, covering a wide range of markets
  • B&K LDS V850 Vibration test system, up to 2.2 kHz, 2-inch travel, multi-axis, accelerated life, and shock testing
  • Tekscan pressure mapping and force measurement
  • Four ESPEC environmental chambers, programmable with remote monitoring:
    • Up to 32 ft³
    • –70 to 150°C
    • 0 – 100% relative humidity
  • Independent pumps supporting a wide range of fluid, pressure, and flow requirements for performance and life testing
  • Digital 50x stereo microscope with measurement and capture capabilities
  • DC drive torque angle for bolted joint development and verification; programmable custom, customer, and production torque profiles up to 112 ft-lbs
  • Five custom NI lab data acquisition units with 14 multi-channel inputs, 50 kHz, variable voltage output control, and 24/7 remote monitoring and control
  • Slurry with ASTM particles and water submersion up to 3 meters with cycling
  • ABS and ESC systems simulation for master cylinder performance and life testing
  • ASTM G155 UV, ASTM B117 salt spray, tensile, shear, and hardness; CMMs, KEYENCE Optical Digital Profiler, and roundness tester
  • MTS 858 tabletop servo-hydraulic actuators (x2), up to 3,000 lbs and 6-inch stroke
  • Production-style Evac & Fill automated system to provide production-level bleed on test parts
  • Online gauge management system with 200+ NIST-traceable calibrated gauges
  • 3D printer with a 14” x 10” x 14” build tray and ABS, ASA, TPU, Diran, and ABS/Nylon-Carbon Fiber material capabilities
  • Dedicated proto-build area in the engineering lab where engineers control and facilitate key builds until production equipment is online
  • Experience working with testing facilities around the U.S. to fulfill any needs that we don’t have at Hayes (Link Engineering, B83 Testing, Element Labs)
Hayes Powersports

Get In Touch

At Hayes, we engineer for the moments that matter—when you push harder, descend steeper, or chase speed. Our bicycle brands represent the frontier of cycling technology, combining deep technical roots with rider-driven insights.