AST Damper Technology - Key Design Principles

AST Suspension is a leader in the aftermarket because they specifically develop, design, and build their products with TUV tests in mind. What are TUV tests and why should you care? Read below:

TUV is an automotive standard that was developed in Germany. TUV was designed to create a standard that gave consumers the highest quality aftermarket parts. Parts must be independently tested by TUV in order to be sold for road use. This is why most products say "track use only". This exhaustive testing far exceeds OEM standards in some cases. AST Suspension is a leader in the aftermarket because they specifically develop, design, and build their products with TUV tests in mind. AST has completed the TUV testing process on many of their suspension kits. While it isn't a requirement in North America to pass these tests, it is by far the most extreme testing for an aftermarket part. Very few shock companies meet these standards, much less specialty racing dampers. The following are key product features that were developed from this testing.

Meeting TUV standards means the best possible quality and safety

AST struts are run through 1 million cycles in testing

AST specializes in providing custom built strut housings for all the makes supported. AST does not build "one off" housings for each kit sold. Housings are built using repeatable manufacturing proceses. TUV's requirement for aftermarket struts involves placing a 500 kg (~1100 pound) load on the side of the housing and running the strut through 1 million cycles. AST struts clear this requirement with flying colors. No noticable wear can be found internally or externally after this test. The struts are required not to leak after this test as well.

Each model is required to use OEM style flanges and bracketry. All original brake line, ABS sensor, brake pad sensor type brackets are found on AST strut housings. Most products of this quality require you to "tie wrap" those hoses to the strut.

AST uses OE style flanges and brackets

Coilover kits with OEM style flanges and brackets

Initial testing and Finite Element Analysis (FEA) determined that the strut body had a highly stressed point located at the end of the threads on the body. Providing a fillet at this point actually strengthens the body.

AST FEA Improves Strenght

Detailed tested yields innovative ways to reduce stress points

AST uses steel - by far the strongest material - for strut bodies

It is often asked if the struts bodies can last in harsh environments such as salt. First of all, all struts are produced using high grade steel as opposed to aluminum, stainless steel and other materials. Steel is by far the strongest, most durable material for this application. AST then coats each body in a process called "KTL" in Europe. This process is not common in North America but is often referred to as cataphoretic dip painting. Dipping the part into a bath all but guarantees complete, even coverage. This provides the best protection against corrosion. This process far exceeds OEM standards on corrosion and is extremely tough.

Each cylinder is dipped into a bath and baked to dry the chemical onto the body. This differs from powder coating where the product is essentially spray painted then baked. Most factory applications use "wet paint", simply sprayed on paint. Struts removed from cars showed no scratches on the body from the installation. Even factory pieces would have nicks in the paint. KTL is expensive and time consuming, two things not condusive to a factory part, but well worth the price to produce the highest quality aftermarket struts.

KTL coating is the superior way to protect against corrosion damage

AST Workmanship Detail

This picture is a close up showing the detailed workmanship that AST puts into every kit.

Each kit comes with OEM quality mounting points and "positive stops" for clamp style struts.
Most kits with baseline spring choices from AST include "AST Orange" springs.

Click here to read about AST Monotube Damper Technology