Research and Development

Life Begins in CAD (Computer-aided-design) Software

Our engineering team begins the design of each of our products as CAD software models where multiple revisions are gone through for both performance and strength maximization as well as for aesthetic cohesiveness. We utilize our 3-D scanning hardware to generate CAD models of OEM equipment as both a base and reference for things such as measurements and materials, while also serving as a benchmark for the stress testing of components.

Once we've created several draft models of a potential product, we undergo software simulated stress-testing that represents forces beyond what would be seen in real world circumstances. This allows us to visualize any potential design alterations that would be required to make a product worthy of a lifetime warranty. It also serves a dual purpose of giving us data used to revise our designs to reduce material where it is not structurally required with the goal of reducing weight.

Rapid Prototyping with 3-D Printing

Using our state of the art 3-D printing hardware, we are able to rapidly create real-world prototypes of our CAD models that have passed stress-testing validation and are ready for fitment validation. With our engineering team having access to both CAD software and 3-D printing hardware, we are able to undergo the initial stages of product design and research and development in-house with rapid alterations based on our printed model feedback. Fitment and clearance concerns can be quickly alleviated before committing to creating a functional prototype, while stress-testing each incremental revision in our CAD software allows us to keep strength and durability at top of mind.

Choosing the Right Materials

Our ethos for selecting raw material comes down to using whatever is best for the application, even if it costs more. The stress-testing of our products will typically include simulating various materials such as 6061-T6, 7075-T6, and Ti-6Al-4V. By simulating all of the common materials used across our product lines, we are able to see if there are any benefits to incorporating or utilizing a different compound on any products under research and development.

We favor using 7075-T6 on machined components where reducing weight is an added benefit (such as unsprung weight on suspension components) or where added tensile strength is beneficial. While this is a more expensive alloy than 6061-T6, there are scenarios where the incremental benefit makes sense from a strength and performance standpoint.

Alternatively we utilize 6061-T6 where added tensile strength is not at all required, and where reducing weight is not a concern. This alloy is also better on components that you may want some more "give" built into it, versus the more "stiff" 7075-T6.

Emphasizing All-Weather Performance

Many of us live in adverse climates, and we know the toll this can do to parts installed on your car. We emphasize all-weather performance on each of our products and we take this into account heavily when it comes to material and finish selection for our engineering team.

We only utilize 304SS for our pillowball bearings on our damper lineup. A common shortcoming of aftermarket suspension is use of standard chromoly steel pillowballs, which are very susceptible to premature corrosion. To simulate an adverse climate, we've tested our 304SS bearings versus the standard chromoly steel alternative in a salt water and peroxide bath. This creates an extremely corrosive environment, and the results speak for themselves.

Similarly, we've elected to utilize an EDP coating (Electrophoretically Deposited Paint) on our shock bodies and mounts. During our anti-corrosion testing, we found that EDP coatings had superior corrorision resistance properties versus powdercoat or more traditional paint options.

We leverage titanium hardware on our products where it is feasible, with our Ti-6Al-4V hardware having incredible corrosion resistance properties. Our titanium hardware is anodized in our Titan Frost finish for added durability.

All of our aluminum components under go a Type II anodizing process which protects them from adverse weather. Type II anodizing creates a protective oxide layer on the aluminum surface that enhances its resistance to corrosion, wear, and abrasion.

Creation of Functional Prototypes

Once we have finished our 3-D printing stage and have selected the materials for our product, we create a functional prototype of the would be end product. For components created via CNC, we are able to fully machine our prototypes in-house for further real world testing on the target chassis.

When it comes to components that we cannot manufacture in-house, we work with our ISO-certified partners who each specialize in their niche of manufacturing. For example for our HRD electronics, we work with a semi-conductor manufacturer who produces our thermistors to our original design.

Final Touches Before Production

With our final drafts in the form of functional prototypes, we are able to install and conduct real world testing of each part before stepping into the production stage. During this stage we are most concerned with intended engineering choices translating to the driver seat, along with the fit and finish of our products.

By gathering real world feedback, we are able to see if any design alterations need to be made by our team before going to production. With the benefit of doing our engineering in-house, revisions are able to quickly be addressed throughout the finish of each product's research and development cycle.

Real World Feedback

With over a decade in the industry, our team has a large network of trusted enthusiasts along with semi-professional and professional drivers who serve as a trusted sounding board for our products. By leveraging our large network of experienced car modifiers, we are able to gather additional feedback from trusted partners outside of our internal team to reduce bias as we work to create the best product possible.

We constantly seek feedback from our network throughout the research and development process to eliminate the threat of engineering within an internal bubble. By eliminating internal bias and receiving valuable feedback from our trusted partners, we are able to further push the limits on each of our products during development. This network also allows us to put our components through a plethora of environments such as purely daily driven cars, heavily modified street cars, and even dedicated track builds - just as they would be for our client base once put to production.

Going to Production

After we've selected our final design, we commit to a test production run. This stage is critical as it is where you can learn shortfalls in documentation regarding processes or quality-assurance. An amazingly engineered part is nothing without a great production process, as it is what brings your products to life.

We keep on-going documentation for the production of each of our products, with the goal of getting better with each passing production run. The purpose of conducting due diligence on documentation and process is also not simply about machining and assembly. For us it is a chance to see our engineering decisions from a new angle. To be able to interact with your product - machine, assemble, install, and use it from start to finish. This perspective often leads to quality of life revisions, which once completed, lead to our first scaled production run with our consumer ready end product and design.

Continuous Evolution

Our team are believers in the continuous evolution of your products, processes, and experiences. When a product launches to production, the progress doesn't stop at HRD. We're constantly dedicating time and resources to plan the next evolution of each of our products. To us it's an internal challenge to continuously push the limits and dedicate ourselves to creating the best experiences possible.

At any given moment, we have about a dozen projects in some stage of research and development. While the HRD brand may be new we're here to make our mark, and that starts with our investment into proper development. Over the coming months we'll be releasing some fantastic suspension arms and linkages, as well as some engine and transmission mounts. It's our ultimate mission to create the premier suspension and chassis component manufacturer around, and it all starts with a dedication to solid research and development.