A brake pad looks simple - a block of material on a steel plate - but it is a carefully engineered composite made from a dozen or more ingredients and cured under precise heat and pressure. Understanding how pads are made explains why quality and price vary so much.
The backing plate
Every pad starts with a steel backing plate - the rigid part that the caliper piston pushes on and that holds the pad in the bracket. On quality pads the friction material is mechanically anchored and bonded to this plate so it cannot separate; a well-protected plate also resists the corrosion that can cause delamination - see the backing plate.
The friction material
The friction compound is a blend of many ingredients: binders (resins), fibers for strength, fillers, and friction modifiers - and the mix defines the pad type. Ceramic pads use ceramic fibers and are quiet and clean; semi-metallic pads use a high steel-fiber content for bite and heat tolerance - see ceramic vs the alternatives and semi-metallic pros and cons. Modern blends are also copper-free by law.
Molding and curing
The powdered friction mix is pressed onto the plate in a mold under high heat and pressure, which cures the resin and bonds everything into a solid. Pads are then baked (post-cured) to drive off gases, and often scorched on the surface for better initial bite. Finally the edges are chamfered and slots are cut - see chamfers and slots - and shims are attached.
Why quality varies
Cheap pads cut corners: less consistent mixes, weaker bonding, skipped chamfers or shims, and thinner plates - which is why bargain pads fade, squeal, or wear fast. Quality manufacturers control the recipe and curing tightly and stamp a compliance edge code. That is the difference you feel in good brake pads paired with fresh hardware.