KW Automotive USA-Plant Tour


Here raw steel stock of varying diameters awaits its turn to get converted to ST Suspensions sway bars.
This computerized cutting saw cuts the stock to preprogrammed lengths.
The saw is hard at work cutting the swaybar segments, a lot of coolant flow is used to extend blade life.  A transducer helps the operator cut the pieces precisely to length.
After cutting, the stock goes to this 3-axis CNC bender where it is bent to the correct configuration. The bender can emulate complex OEM bends, which is important because on many late model cars, the sway bar is packed very tightly around a bunch of components.  Less sophisticated benders sometimes cannot produce a bar that will fit in these situations, much less a performance bar that is larger in diameter.
Accurate bending is the heart of a proper sway bar. Bad bends can cause interference with the car's components, poor fitment and mess up corner weights.  After struggling getting some aftermarket swaybars to fit, we can appreciate this!
KW uses this induction heater to soften the swaybar's end so they can be swedged into shape. Swedging produces a one piece bar with is potentially stronger than a bar with welded in ends. The induction heater is sort of like a microwave oven for metal using a magnetic field to heat the part to over 900 degrees in a matter of seconds.

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