Patent ID: 8006740

Claim:
A method of forming a brake rotor comprising: forming a plurality of annular metal insert portions, each insert portion having an inner side and an outer side; forming a plurality of attachment members coupled to and extending outwardly from the inner side; forming a plurality of slots in the insert portions, the slots having a depth coextensive with a thickness of the insert portions, the slots extending radially inwardly from an outer circumference of the annular insert portions; the slots being spaced apart about the circumference such that a plurality of attachment members are positioned between each pair of adjacent slots; positioning the plurality of insert portions into a mold using a magnetic attractive force to retain the insert portions within the mold such that the inner side of one of the plurality of insert portions faces the inner side of another one of the insert portions; introducing a molten aluminum into the mold such that the molten aluminum contacts the inner side of each insert portion; and forming a mechanical coupling between the aluminum and at least a portion of at least one of the inserts.