Automotive Technology
Automotive Technology
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Shock Absorbers Without Limits
What do industrial washing machines, street sweepers, and earthquake-resistant buildings have in common with a performance vehicle? In all these cases, the key is to precisely control movements and reduce vibrations. BILSTEIN, part of the thyssenkrupp Aftermarket Group, develops customized shock absorber solutions for this purpose within its Special Customer Projects division—going far beyond traditional automotive applications.
A particularly unusual example comes from the industrial sector: For a manufacturer of large industrial washing machines, BILSTEIN developed a custom shock absorber solution based on a shock absorber that was originally designed for the VW Beetle. The solution remains successful to this day.
What may seem unusual at first glance follows a simple technical principle: wherever movements need to be controlled, vibrations reduced, or components protected from high loads, dampers can play a crucial role. This applies to vehicles as well as to machines, buildings, or infrastructure.
From the Road to New Areas of Application
“Most people associate shock absorbers with cars. In fact, the range of applications extends much further. Today, BILSTEIN dampers are used in industrial washing machines, logistics systems, airport tugs, street sweepers, and work vehicles—and even on playgrounds,” says Uwe Kausch - Global Project Coordinator - Special Customer Projects.
In street sweepers, for example, the dampers do not perform a traditional suspension function. Instead, they ensure controlled movement and high durability of brush assemblies under demanding operating conditions.
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Special damper solutions are also used in logistics and conveyor systems, as well as in airport tugs. Industrial applications often place special demands on temperature resistance, load-bearing capacity, service life, and corrosion protection.
Applications in infrastructure are even further removed from the traditional automobile. In Japan, for example, BILSTEIN dampers are used in building damping systems in earthquake-prone regions. As part of the building structure, they help absorb vibrations and increase the stability of structures. Other specialized applications can be found on cable-stay bridges or in bow thrusters, which assist cruise ships with lateral maneuvering in ports.
Solutions for Special Requirements
At BILSTEIN, these applications are handled by the Special Customer Projects (SCP) division. Positioned between the traditional aftermarket business and the OEM sector, SCP focuses on projects specifically tailored to meet special customer requirements.
The spectrum ranges from recreational vehicles and performance cars to small-series manufacturers, as well as industrial and infrastructure applications. The starting point is always the customer’s specific requirement.
This does not mean that a shock absorber must be developed from scratch for every project. Often, proven technologies and components from the BILSTEIN modular system can be utilized. Depending on the application, factors such as installation space, damping characteristics, durability, or corrosion protection are adapted. New technical concepts are also developed to meet special requirements.
The technical principle remains the same: a shock absorber controls vibrations and converts kinetic energy into heat. In a vehicle, the interaction between the spring and the shock absorber ensures that the wheels maintain as constant contact as possible with the road surface—a key prerequisite for stability, safety, and comfort. This expertise can be applied to numerous other applications.
From Off-Road Vehicles to Small-Volume Production
Even within the automotive sector, the demand for customized solutions is growing. One example is the off-road sector. Heavier vehicles and more complex body structures place special demands on the suspension. This calls for shock absorber systems that are specifically tailored to the vehicle, its weight, and its intended use.
The same applies to performance vehicles, special editions, and smaller vehicle manufacturers. Flexible development and manufacturing processes are particularly important when dealing with relatively small production runs.
The “heart” of Special Customer Projects is in Ennepetal, Germany. Every customer inquiry is evaluated individually and technically developed. At the same time, the division draws on comprehensive development and manufacturing expertise within thyssenkrupp. The spectrum ranges from small series starting at around 50 units to special projects for OEM customers with development times spanning several years. Development takes place in Germany and Romania, while production occurs at thyssenkrupp locations across Europe.
Working Together to Find the Right Solution
Especially outside the automotive industry, it is not always clear at the start of a project exactly what the technical solution should look like. The specific requirements profile is therefore often developed in collaboration with the customer.
“The projects are tailored to specific customer requirements and often demand a high level of development and application expertise. This requires intensive collaboration with clients based on a spirit of partnership,” says Michael Fritz - Manager Product Design Special Projects.
BILSTEIN specialists support projects from the initial idea through to series production, drawing on their experience across various industries. A specially developed SCP app serves as a central platform for information and project management. It helps coordinate the multitude of ongoing projects and systematically leverage existing knowledge.
Growth Through Specialization
For BILSTEIN, Special Customer Projects are more than just custom technical solutions. This division is one of the growth drivers of the aftermarket business and opens up additional applications and customer groups. BILSTEIN is seeing rising demand, particularly in the off-road and industrial sectors.
“Whether it’s a special-edition performance series, a street sweeper, a bridge, or a building damper—customer-specific requests demonstrate just how versatile modern damping technology can be,” says Andreas Verhoven - Head of Special Customer Sales. That is precisely where the potential of Special Customer Projects lies: Proven damping technology continually opens up new applications and business opportunities.