Custom Sway Bar Bushings
Engineering Build Sheet
We manufacture made-to-spec sway bar bushings for OEM, performance, and industrial applications. No catalog parts. 100% built to your drawing or CAD.
Fitment Window Parameters
Design Variants Configuration
Split Bushing
Single cut or double cut design for easy installation over the bar without removing end links.
Fast assembly, retrofit friendly.
Requires rigid housing to close gap.
Grease Grooved
Internal channels (helical, axial, or diamond) to retain lubricant and prevent squeak.
Low friction, extended service life.
Higher tooling complexity.
Bonded / Sleeve
Bonded inner sleeve or fabric liner. Can be bonded to outer shell.
Zero squeak, controlled torsional stiffness.
Higher cost, complex manufacturing.
Technical Specifications Matrix
| Parameter | Capabilities & Standards |
|---|---|
| Material Options | Polyurethane (Cast/Injection), Natural Rubber (NR), EPDM, Silicone, Neoprene |
| Hardness Range | 40 Shore A (Soft) to 75 Shore D (Hard / Rigid) |
| Dimensional Tolerance (ID/OD) | Precision: ±0.05mm | Standard: ±0.20mm | ISO 3302-1 Class M2 |
| Concentricity / Runout | < 0.15mm TIR (Total Indicator Reading) |
| Surface Finish | Ra 0.8µm – 3.2µm (Mold Finish: SPI A2 to D2) |
| Sleeve / Insert Materials | Stainless Steel (304/316), Aluminum (6061/7075), Brass, PTFE Liner |
| Lubrication Strategy | Internal Grease Grooves, Molybdenum Disulfide (MoS2) Additive, Graphited PU |
| Temperature Range | -50°C to +150°C (Material Dependent) |
| Chemical Resistance | Resistant to: Road Salts, Oils, Greases, Ozone, UV, Brake Fluid |
| Inspection Methods | CMM, Optical Comparator, Durometer Gauge, Rheometer (Cure Analysis) |
Quality Assurance & Traceability
Our quality management system aligns with IATF 16949 standards. Every batch is traceable from raw material lot to final shipment.
Incoming Material Verification
Raw polymer FTIR analysis and hardness verification before molding.
Lot Traceability
Laser marking or mold dating available for batch tracking.
In-Process Controls
Hourly dimensional checks and visual defect monitoring.
Sample Inspection Report Evidence
NVH & Squeak Control Playbook
| Symptom | Root Cause | Engineering Mitigation | Verification |
|---|---|---|---|
| Squeaking / Chirping | Dry friction slip-stick between bushing and bar. |
|
Dry-run oscillation bench test (10k cycles). |
| Clunking / Knocking | Tolerance stack-up gap or material compression set. |
|
Static load deflection & Compression set test. |
Manufacturing & Validation Route
Application Scenarios
Daily Driver / OEM
Prioritizing NVH absorption and long maintenance intervals. Rubber or soft PU (65A-75A).
Off-Road / 4×4
High articulation requirements. Abrasion resistant compounds for mud/grit environments.
Track / Performance
Stiffness focus for direct handling response. Rigid PU (90A-75D) or Delrin inserts.
Industrial / Heavy Duty
Massive load bearing capacity. Chemical resistance for hydraulic fluid exposure.
Ready to validate your design?
- Custom-only manufacturing (No off-the-shelf)
- Full engineering drawing review
- Comprehensive inspection evidence
Engineering FAQ
What is the best durometer for custom sway bar bushings?
For street applications, we recommend 70A-80A Polyurethane to balance performance and NVH. For track use, 90A-95A provides better response. For off-road, 75A-85A is common for articulation.
How do you prevent polyurethane bushings from squeaking?
We engineer squeak reduction through three methods: 1) Designing internal grease grooves (axial/diamond) to retain lubricant, 2) Using self-lubricating compounds (graphite/teflon infused), or 3) Bonding a fabric liner to the ID.
Do you manufacture split vs solid bushings?
Yes, we manufacture both. Split bushings (single or double cut) allow for easier installation without removing the sway bar links. Solid bushings are preferred for maximum stiffness but require sliding onto the bar end.
What is the standard lead time for custom tooling?
For custom sway bar bushings, tooling typically takes 15-20 days depending on complexity. First article samples (T1) are provided immediately after tooling completion for validation.
What files do I need to send for a quote?
Please provide a 3D CAD file (STEP, IGES, or X_T) and a 2D PDF drawing with critical tolerances (ID, OD, Width) and material specifications. If you only have a sample, we can reverse engineer it.
Can you achieve interference fits for the housing?
Yes. We calculate the appropriate oversize factor based on your housing ID and the material’s compression modulus to ensure a snug, movement-free fit within the bracket.
Do you offer metal sleeve inserts?
Yes, we can supply and bond metal sleeves (Stainless Steel, Aluminum, Zinc-plated Steel) to the bushing to prevent wear on the sway bar and ensure proper bolt torque retention.
What are your environmental capabilities?
Our materials are formulated to resist road salts, oils, ozone, UV radiation, and temperatures ranging from -40°C to +120°C, ensuring longevity in harsh under-chassis environments.
Start Your Project
Send us your drawings or specs. Our engineering team will review your requirements and provide a DFM report along with your quotation.
sales@rapidaccu.comOur Location
Rongli Industrial Park, Dalang
Longhua District, Shenzhen, China