Maximizing payload performance with high-load truck suspension springs

Explore how Lesjöfors engineered a series of robust and durable truck suspension springs to meet the increasing payload demands of the pickup truck industry.

A red pickup truck drives on a sunlit, winding road through a desert landscape, with mountains in the background and a yellow curve sign ahead.

Project overview: enhancing truck suspension

The life of a pickup truck is demanding. Built for work without compromise, trucks need reliable handling across varied and often rugged terrain. Beneath the tough exterior lies a carefully engineered suspension system, designed to manage load, stability, and long-term durability under repeated use.

In the UK market, there was a growing demand for increased payload capacity. Meeting this challenge required a purpose-engineered solution in high-load truck suspension springs – and this is where Lesjöfors comes in.

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A side angle view of a black compression spring for suspension systems

Design criteria: engineering truck suspension springs

What was the brief?

The brief was to custom design a nest of springs that addressed a recurring weight issue, while extending previous performance limitations and reducing suspension spring damage in heavily loaded trucks.

What makes the project special?

The project was particularly special because the collaborative work between truck specialists and Lesjöfors also led to the development of new suspension springs for wheelchair-accessible mobility vehicles.

Two workers discussing a metal component in a production environment.

Design criteria: engineering truck suspension springs

What did Lesjöfors do?

Working closely with the customer and gaining a detailed understanding of their requirements and specifications, we designed and manufactured a spring solution that resolved previous weight issues, reduced performance limitations, minimized damage, and improved overall operational cost effectiveness.

What challenges did Lesjöfors overcome?

When UK importers bring pickup trucks into the market, the vehicles are typically configured with lighter payload capacities and require modification to handle heavier UK load requirements. Our team not only designed and developed a truck spring suspension solution to meet these demands, but also achieved UK type approval – a significant technical and regulatory challenge.

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What our clients say

Increased efficiency and reduced costs

"Heavy loads put additional pressure on vehicle suspension. This can cause a range of issues, such as reduced brake efficiency, tyre wear and difficulty in steering. It also leads to additional costs, which we have hugely reduced thanks to our new Lesjöfors suspension spring design."

Truck industry leader

Rows of metal coil springs hanging from a production rack inside Lesjöfors’manufacturing facility

Manufacturing truck suspension springs

The objectives of the project were strategically aligned with the manufacturing infrastructure of Lesjöfors.

With some of the most advanced CNC coiling manufacturing facilities available, our team of engineers developed several designs, worked up prototypes and samples, utilized our 3D scanning facilities, and subsequently delivered a truck suspension spring that exceeded expectations.

In terms of material selection, the application demanded high-quality chrome silicon, which was cold coiled, heat treated, shot peened, and then powder coated in line with the customer's specific demands.

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Truck suspension springs: from prototype to production

Close collaboration between the customer and our customer service team, account managers, and engineers is crucial to the success of a project like this.

Managing detailed specifications to not only deliver a spring solution that resolves the customer’s challenges, but also delivers a cost-effective product line, requires a coordinated team effort.

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