Abstract: A method for enhancing the physical characteristics of a localized area of a suspension component by adding material to the points of high stress without a significant increase in weight or diameter of the suspension component. The material is in the form of a sleeve added to the exterior surface of the suspension component, a core added to the interior surface of a tubular suspension component, winding filaments, or powered material.

Abstract: A method of varying the bend radius while forming a stabilizer bar is achieved by varying the radius of the forming tool over which the stabilizer bar is bent. The bend radius of the stabilizer bar is varied by changing the position and/or shape of the forming tool in relation to the stabilizer bar. The stabilizer bar is formed by bending the bar over the forming tool to create a bend of desired radius. In the disclosed embodiments, the forming tool is bent chain, a conical tool, and an eccentric shape with several distinct radii.

Abstract: A method of enhancing the bending process of a stabilizer bar by locally pre-heating the stabilizer bar immediately prior to formation. By pre-heating the stabilizer bar, the stress in the stabilizer bar is relieved at the bending areas. This allows larger bars to be formed which would otherwise be outside of machine parameters. In the disclosed embodiments, the stabilizer bar is locally heated by induction coils or resistance heating at the bend areas.

Abstract: A stabilizer bar is provided having a varying cross-section along the length of the bar. In particular, the stabilizer bar includes a first cross-sectional area and a second cross-sectional area that is different than the first cross-sectional area. A first surface at least partially defines the second cross-sectional area. The first surface has a non-circular shape with primary and secondary load bearing directions bearing different maximum loads in each of the directions. The shape of the second cross-sectional area may be arranged so that the primary load bearing direction is generally aligned with the highest load. Similarly, the shape of the second cross-sectional area may be arranged in a manner to bear the highest torsional load. The stabilizer bar may be solid or hollow. Preferred shapes may include egg-shaped or elliptical shaped surfaces. Alternatively, the stabilizer bar may have a generally uniform cross-sectional area along its length with the non-circular shape described above.