Bumpstops - Special Foam Bumpstops

POWERFLEX Bump Stop Spring Aids Bump Stops and Spring aids are becoming an increasingly important component in the overall chassis package. They are no longer used as just a component to stop the shock absorber bottoming out but an important part of the spring and damper package, contributing to the overall handling of the car.

With advances in polyurethane technology the bump stop has become an integral part of the chassis. Now vehicle manufacturers are using them as secondary springs to control ‘on the limit’ handling.



Advanced foam bump stops allow chassis engineers and shock absorber manufacturers to achieve a truly progressive spring rate across a long travel shock movement. This illuminates having to use springs which are designed to coil bind to change their rate.



Long spring aids which start to come into operation after very small shock deflections can help to provide true, controlled spring progression throughout long travel shock movements. Shock manufacturers and chassis engineers are demanding more and more performance from the suspension components but are getting limited performance from bump stop manufacturers.



As a result, POWERFLEX have now invested heavily in the most advanced, materials, manufacturing equipment, CAD systems, 3-D tooling manufacturing and dyno testing facilities. All of these facilities are in-house and completely under our control.



With these new facilities we are developing a range of high performance closed cell foam spring aids to our own designs. These parts come with accurate force/deflection curves and are made as a universal product for all popular shock rod diameters including 10mm – 12mm – 14mm – 5/8” – 16mm – 19mm – 20mm – 22mm.



Our raw material is a proven closed cell polyurethane which has been developed to offer exactly the properties required in a spring aid. Unlike some bump stop foams which have an open cell structure. Open cell structure foam will absorb water causing premature component failure when wet under load or in sub zero conditions. Another problem with open cell foams is the air being crushed out of the smaller cells is blown directly into the neighbouring cells, again causing premature failure of the bump stop. The closed cell foam we use has very consistent physical properties from -40 to 80C.



Another significant advantage that POWERFLEX offer is the ability to vary the physical properties of the spring aid within the same tooling during the manufacturing process. This means that should you require an increase in the load/deflection characteristics of a part this can be done without the cost of new tooling.



Uniquely, we can manufacture high quality tooling on an exclusive basis, very quickly and at sensible costs. We have looked closely at the bump stop manufacturing market and have been surprised to find out that many shock absorber manufacturers use an “off the shelf” bump stop, usually not suitable and requiring physical modification to suit the application.



We have the facilitys to make new tooling for new designs and are able to provide force/deflection data. Our customers can specify the design and we can work together to achieve specific physical properties. We would be pleased to discuss your requirements. We can provide sample parts immediately using our existing production facilities.



POWERFLEX bumpstops – your design, your specification, your solution.