Behind the scenes
We manufacture our ST coilovers at the KW automotive headquarters in Germany. We assemble and produce all components for our coilovers in the mechanical production department. We manufacture every coilover suspension to order.
System development & testing
Our suspension systems are based on a unique combination of innovative technologies. Development takes place under laboratory conditions - by one of the most creative and experienced teams, supported by a state-of-the-art test centre.
CAD design of new systems
Intensive data research is followed by initial calculations and sketches, created using specially developed tools and modern CAD programmes. This creates a clear picture as a basis for further development.
Virtual simulation of components
By precisely analysing various parameters such as fluid mechanics and (fatigue) strength, we take individual customer requirements into account at an early stage, check design decisions and simulate extreme situations virtually - without any material wear.
Analysing hydraulic valves
We simulate realistic loads using endurance and flow test benches to ensure perfect performance in subsequent use. Interference factors are eliminated so that the valve can be analysed as a single component. This enables us to detect potential faults at an early stage and rectify them immediately.
Endurance test
On our high-performance test benches, we put each of our developments through their paces in the most extreme conditions, from fast corners on the road to brutal drift maneuvers. All of this can be achieved without driving a single kilometer. Maximum reliability, no nonsense. Your ST suspension is ready for anything.
Application development & tuning
Every ST suspension is created in a sophisticated development process with the help of high-tech tools, a great deal of expertise and genuine passion. Not simply tuned, but developed specifically for your vehicle model from the outset, our products fit like a glove.
Data acquisition
Before we dedicate ourselves to the actual supreme discipline - development - we collect data: We collect relevant information on installation spaces, analyse competitor products and check which findings from past projects are transferable.
Prototype construction
This is where the first real performance precursor is created. We mill, turn, and build almost all parts ourselves at our headquarters in Fichtenberg, Germany, and then put the prototypes through their paces in our extensive test center. If everything runs smoothly, the product will soon find its way into your car.
Installation of the prototypes
After our design engineers have checked the technical requirements of the series parts in the CAD programme, we produce a prototype. We then test this using our test plan. If this runs smoothly, the prototype is installed in the vehicle.
Dynamic load simulations
Once the prototype is in the vehicle, we test the ground clearance and wheel clearance under various loads. This gives us the initial basis for the later, ideal damper setup for your car.
Objective suspension tuning
Our highlight in the test field: the 7-post test rig. We use it to test the suspension and vehicle under realistic conditions - for precise performance on the road and on the racetrack.
Test drives for fine tuning
After the vehicle and chassis have passed all the endurance tests, our engineers scrutinise the balance, comfort, wheel control and driving feel on a real test track.
Build to order
In order to deliver a unique product to every customer, we have established a fully digitalised and largely automated production process.
Warehouse logistics
We have more than 26,000 storage locations available in-house. All process chains - from incoming goods to damper and chassis assembly through to dispatch - are automated. Each required component is automatically assigned to the systems.
Powder coating
We give the raw spring its final look at the KW automotive headquarters. This is where the coating with one of 18 selectable RAL colours and the labelling of the main spring takes place.
Housing production
The housings for our coilover suspension systems are manufactured in our mechanical production facility: Here we cut the tubes to size, weld them precisely with brackets and protect them with high-quality galvanising.
Valve production
Compression and rebound valves are customised to your vehicle model. We assemble even the smallest components such as valve plates by hand with millimetre precision.
Damper assembly
Our dampers are made by hand - with great attention to detail and the aim of achieving maximum performance. From individual parts in the three-digit range, a high-performance damper is created in the end.
Final assembly
All ST products are given the finishing touches in our final assembly department. Whether spring assembly, bump stop, dust protection or packaging: an ST product is only ready for use when every detail is in place.
Quality control
Quality is our focus at every step. Every product is checked several times during assembly - for perfect function and a flawless appearance.
Packaging
Our ST products are packaged securely and robustly - so your order is well protected until it arrives. All relevant documents are included in the scope of delivery, vehicle-specific and in the appropriate national language.
