Research and Development

Life Begins in CAD

Every HRD part starts life as a CAD model, not a guess. Our engineering team builds each product digitally first, iterating through multiple revisions to maximize performance, strength, and aesthetic cohesiveness as a single system. We use high-precision 3D scanning to capture OEM components and geometry, giving us a reference point for fitment, material behavior, and packaging, and a benchmark for how much further we can push strength and durability.

From there, we run aggressive software-based stress testing that simulates forces well beyond what the part will see in real-world use. This lets us identify and resolve potential weak points long before metal ever hits a machine, and it sets the bar for what we consider “lifetime warranty worthy.” At the same time, these simulations guide us in removing material where it isn’t structurally required, trimming weight without compromising safety or performance.

Rapid Prototyping with 3D Printing

Once a design passes our virtual testing, it moves into the physical world via our in-house 3D printing capabilities. With state-of-the-art printers sitting next to our CAD workstations, we can quickly create tangible prototypes for fitment and clearance validation. This tight loop between digital and physical allows us to update designs in hours, not weeks, based on real feedback from the chassis.

By solving potential packaging and interference issues with printed prototypes, we avoid costly surprises when it’s time to cut functional parts. Every incremental revision is re-validated in CAD for strength and durability, so by the time we commit to a working prototype, we already know it meets our internal standards for both performance and reliability.

Material Selection with Purpose

We don’t choose materials based on what’s cheapest or most common. We choose what’s correct for the application, even if it costs more. During development, we simulate multiple alloys, including 6061‑T6, 7075‑T6, and Ti‑6Al‑4V, to understand how each behaves under the specific loads that part will see. By modeling all of the common materials used across our product line, we can identify where a higher-spec material provides a real advantage and where it doesn’t.

We favor 7075‑T6 for machined components where reducing weight is a performance multiplier, such as unsprung mass in suspension components, or where additional tensile strength is critical. It’s more expensive than 6061‑T6, but in the right application, the incremental gains in strength and performance justify the choice. Conversely, we utilize 6061‑T6 where extreme tensile strength isn’t required and where a bit more “give” in the component is desirable. This makes it ideal for parts where controlled flex is beneficial and where weight reduction isn’t the primary goal.

Built for All‑Weather Abuse

Real cars live in the real world. Rain, snow, salt, heat, and everything in between. We design every HRD product with all‑weather performance as a core requirement, not an afterthought. That starts with material and finish selection aimed directly at fighting corrosion and long-term degradation.

On our damper lineup, we exclusively use 304SS for pillowball bearings, avoiding the common aftermarket shortcut of standard chromoly steel, which is highly susceptible to premature corrosion. To replicate harsh environments, we test 304SS against chromoly in a salt water and peroxide bath, creating an extremely corrosive setting that quickly exposes weaknesses. The results speak clearly in favor of 304SS.

For our shock bodies and mounts, we utilize an EDP (Electrophoretically Deposited Paint) coating after finding it offered superior corrosion resistance compared to powdercoat and traditional paint options during internal testing. Where feasible, we leverage Ti‑6Al‑4V titanium hardware for its excellent corrosion resistance and strength, finished in our Titan Frost anodizing for added durability. All aluminum components go through a Type II anodizing process, creating a protective oxide layer that significantly improves resistance to corrosion, wear, and abrasion.

Functional Prototypes & Real‑World Testing

After 3D printing validation and material selection, we move into functional prototype creation. For CNC-based components, we fully machine prototypes in-house, allowing us to install and test them on the target chassis under real driving conditions. This hands-on stage is where engineering intent meets driver reality. We evaluate not just strength and performance, but also installation experience, clearances, and overall feel.

For components we cannot manufacture internally, we partner with ISO‑certified specialists who are experts in their specific manufacturing disciplines. For example, our HRD electronics utilize a semiconductor partner that produces thermistors to our exact specifications and original designs. Whether made in-house or with partners, every prototype is subjected to the same scrutiny before it’s allowed to move forward.

Real‑World Feedback, Not a Bubble

Data and simulation matter, but the car still has to make sense from the driver’s seat. With over a decade in the industry, our team has built a large network of trusted enthusiasts, semi-professional, and professional drivers who act as an external sounding board for our products. We rely on this group to help eliminate internal bias and ensure we’re not engineering in an echo chamber.

Our components are tested across a wide range of real scenarios: daily driven cars, heavily modified street builds, and dedicated track machines. By gathering feedback from this network throughout the R&D process, we’re able to refine feel, feedback, and durability in ways that raw numbers alone can’t capture. Pushing each product closer to the standards our customers expect.

From Pilot Runs to Continuous Evolution

Once a design is finalized, we commit to a test production run. This stage is where process and documentation are stress-tested just as thoroughly as the part itself. An exceptional design is worthless without a repeatable, high-quality production process. Test runs help us identify gaps in machining instructions, assembly procedures, and quality assurance, and they give us a chance to interact with the part from every angle. Machining, assembling, installing, and using it end-to-end.

We maintain living documentation for every product, improving our processes with every production cycle. This often leads to quality-of-life revisions that simplify installation, enhance durability, or refine the overall experience before we move into scaled production for the end customer. Even then, the work isn’t “done.” Our team believes in continuous evolution. Products, processes, and experiences are always in motion. At any given time, we have roughly a dozen projects in some stage of R&D, from new suspension arms and linkages to engine and transmission mounts.

HRD may be a newer brand, but we’re not here to blend in. Our goal is to become the premier suspension and chassis component manufacturer in the space, and that begins with a deep, ongoing investment in proper development. Every part that wears our name is a direct product of that commitment.