Kenny Millar SFX

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Brake Boosters

Using iBooster in movie prop vehicles

Brake boosters on test

Sometimes when making a movie or TV show, you need a vehicle to do something that is not safe with a squishy human inside. Like an F1 Car crashing into a pit lane wall, or a Cessna aircraft careening out of control down a runway.

For these vehicles you need remote controls, and part of that might include a braking system.

One useful tool for implementing remotely controlled brakes is the Bosch iBooster found in Tesla vehicles (and others).

I designed and built a number of electronic controllers for iBoosters that were used in the filming of “The F1 Movie” and “The Dog Stars”.

These controllers use advanced MCUs and multiple CAN interfaces in a totally unique and bespoke design of my own, which gives movie makers complete control over the brake booster, allowing everything from gentle braking to full emergency stop. The controllers have full control over the movement of the brake piston in the master cylinder. Multiple units can be used together.

They were used alongside a full e-stop system that can apply the brakes in the event of an estop signal, power failure, mechanical failure or any number of other events. The e-stop system was pneumatically powered. It required fast regular periodic watchdog signals from the brake controller to know that all was well. In the event of any kind of failure or ambiguity it would release a piston to physically apply the brakes.