This work presents a thermal and static structural analysis on brake discs used in light vehicles for a paved road. Then, with the results of the analysis mentioned above, a parametric sensitivity analysis on brake disc geometry can be made based on the design of experiments method. The complete study for industrial or automotive brake systems requires a set of knowledge, including solid mechanics, dynamics, heat transfer, tribology and fluid mechanics. Brake system analysis is so complicated that most industries decide to create physical experiments in order to validate the component, instead of modeling it. Physical contact phenomena in the braking process should be investigated gradually in favor of reliability of the component in study. In this context, achieving a reliable analytic and numeric model may assist significantly in predicting the brake system's behavior faced with different brake conditions and situations as well as embodying the physical phenomena in order to virtually evaluate brake discs' behavior. As a result, from the design of experiment method developed in this study, brake system designers must be careful about sizing thickness and inner radius of brake discs. These two factors highly interfere with maximum temperature, Von Mises stress and brake disc mass.