Sphere Brakes, LLC is making history by developing the first commercial sphere brake system. Our patented technology leverages inherent design to outperform air disc and drum brake systems in a much smaller package, unlocking new opportunities for the commercial vehicle and the Department of Defense (DoD) tactical vehicle industries.
Meet the Founder
Aaron Lewis, P.M.P., Co-Founder and CEO

Aaron is a technologist and licensed project manager with demonstrated leadership proven by 14 years of successful strategic military and business management.  Prior to co-founding Sphere Brakes, LLC, Aaron served over 12 years in the military and led several business operations at GE Transportation in Erie, PA.  He holds a Master’s Degree from Penn State University.

Build – Measure – Learn

We are unlike our competitors because we leverage the power of the Build – Measure – Learn feedback loop to deliver new brake systems at a fraction of the cost while operating with flexibility as a lean start up in the auto industry. The strengths of Sphere Brakes are its people, practices, and unwavering customer service.

1. People

Our team consists of high achievers with unquestionable integrity.  The value-add is immediately evident when interacting with clients and manifests itself through the feedback we receive from our customers and partners.

2. Practices

We fit our solutions to the customer, not the other way around.  We tailor to each individual customer based on their requirements and organization structure and processes through routine Voice of Customer (VOC) visits and meetings, confirming to ISO 9000 and 21500 standards in quality and project management.

3. Customer Service

We are with our customers every step of the way.  Whether we visit local maintenance shops, regional fleet owners, or conduct MVP review days showcasing and assessing products in development – our hands-on approach ensures that an engagement will not end until our customers and partners are completely satisfied with the deliverables.

Sphere Brakes perform. I'm very excited about Sphere brakes for a few reasons. It performs as-good and better than a disc brake with less up-front and maintenance costs. It's much safer for our technicians to replace the brake pad because you do not have to remove the wheel. For these reasons, we're excited to integrate Sphere Brakes into our fleet. - Harold H. Bender - President, Team Hardinger


Sphere Brakes, LLC has created two new minimum viable (MVP) brake technologies, the air sphere service brake and the sphere brake driveline retarder. These systems directly compete with air disc brakes, air drum brakes and electromechanical brake retarders in size, weight and performance. We are focused on optimizing this sphere brake technology by aligning with strategic partners in the commercial vehicle and Department of Defense industries.
Air Sphere Illustration
Air Sphere Service Brake

In service brake applications, the patented sphere brake technology leverages s-cam actuation, but in compression in lieu of expansion.  When the brake is applied, segmented hemispherical pads enclose on an outer segmented sphere surface.  This inherent design allows multi-directional brake force application around the brake surface generating more torque with a smaller brake effective diameter.

Sphere Brake Driveline Retarder

In a driveline retarder application, the sphere retarder is mounted in line with the drive shaft between the transmission and drive axles; however, it is actuated by an electric over hydraulic system controlled by the driver using battery power. Like the service brake, hemispherical pads compress a sphere brake surface in a wet-pack enclosed housing.

Press Releases


Ben Franklin Technology Partners

Ben Franklin Technology Partners (BFTP) has partnered with Sphere Brakes, LLC to stimulate economic growth and development in Pennsylvania.  For more than 31 years, BFTP has provided both early-stage, technology-based firms and established manufacturers with funding, business and technical expertise, and access to a network of innovative expert resources.  BFTP is an initiative of the Pennsylvania Department of Community and Economic Development and is funded by the Ben Franklin Technology Development Authority.  http://benfranklin.org

Thomas D. Larson Pennsylvania Transportation Institute

Sphere Brakes, LLC has partnered with the Thomas D. Larson Pennsylvania Transportation Institute (LTI) to conduct vehicle testing and MVP reviews.  LTI is Penn State University’s (PSU) transportation research center.  Since its founding in 1968, LTI has maintained a threefold mission of research, education and service.  The Institute brings together top faculty, world-class facilities and enterprising students from across the University in partnership with public and private stakeholders to address critical transportation-related problems.  http://www.pti.psu.edu

Contact Us.

Contact Details

We want to hear from you!  Please use the contact form to submit your message, or call us directly at (814) 440-5164.  We promise to get back to you in an extremely timely fashion.

Sphere Brakes, LLC
3120 Norcross Road
Erie, PA 16510

(814) 440-5164

Tel: (814) 440-5164

Let’s get in touch

Aaron Lewis @SphereBrakes Leveraging the power of #additivemanufacturing at the #InnovationCommons @PSBehrend to develop new #technology for… https://t.co/IRX9wx8j8p 1 day ago
Aaron Lewis @SphereBrakes Attended the @costarters press conference this morning at the Blasco Library by the IdeaLab to support community… https://t.co/ULjdooxxZP 1 week ago
Aaron Lewis @SphereBrakes We introduced @SphereBrakes to the #heavytruck industry securing our first US based global customer in under two ye… https://t.co/NifaqBkg8P 4 weeks ago
Aaron Lewis @SphereBrakes Growing up #racing #motocross taught me the #skills to become a successful #Entrepreneur!!! #TakeRisks #GoForIthttps://t.co/Ke6KK0pMkF 7 weeks ago
Aaron Lewis @SphereBrakes RT @ErieBAT814: Innovation Districts - Opportunity is Knocking in #Erie #PA https://t.co/pVtlUB4zT9 7 weeks ago
Aaron Lewis @SphereBrakes RT @ralph_ford: Leveraging the strengths of our universities through this network of Innovation Beehives. @BenFrankBrian @ErieTechnology 14 weeks ago
Aaron Lewis @SphereBrakes I'm attending Ruck The Bay 2017 to end Veteran Homelessness! Please join me for the 15K - https://t.co/corTvyPt2Z #constantcontact 16 weeks ago