Carbon-carbon composite disc brake assembly

A method of forming a disc brake assembly comprising:

• forming a core structure comprising a carbon-carbon composite material, wherein the core structure defines an inner and outer diameter, the core structure having a first major surface comprising at least one curved ridge or curved channel that curves as the curved ridge or curved channel extends in a radial direction along the first major surface between the inner and outer diameter of the core structure;
• forming a plurality of wear pads, each wear pad comprising a carbon-carbon composite material and defining a friction surface and a mounting surface, wherein the mounting surface of at least one wear pad of the plurality of wear pads comprises a corresponding curved ridge or curved channel that curves as the corresponding curved ridge or curved channel extends in the radial direction along the mounting surface, wherein the corresponding curved ridge or curved channel is configured to interlink with the at least one curved ridge or curved channel of the core structure;
• and
• assembling the plurality of wear pads on the core structure, wherein the mounting surfaces of the plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure.