Pushing Potential Further: Braselton Test Team

Every Test Matters

When a driver pushes their vehicle, the first thing they describe is how it rides, the handling, and the overall experience. Just imagine conquering a rocky trail where the suspension is just soaking up every bump with confidence. Or hitting the highway and feeling comfort and control no matter the speed. That’s where the suspension system plays a major role and why every test in the design and manufacturing process matters.

Suspension systems can change the entire experience and capabilities of a vehicle, and in motorsport it can be the delineating factor that brings victory. With new vehicles and technology, the importance of testing is growing, and Fox Factory test teams are throwing everything at each product at every step of the process. So, let’s walk through the process:

Concept Phase

During this initial phase, design and application engineers bring shock designs to life. With a particular vehicle and use case in mind, prototype parts are created with tight tolerances using high-precision techniques like CNC machining. These prototypes are then subjected to initial testing on a dyno to assess their basic functionality and performance.

“Our test team in Braselton will typically go through testing throughout the process to ensure it assembles and performs as intended,” said Manager of Test Engineering Chris Rohde. “There are a number of testing iterations we put the product through, especially on new technology.”

Development Phase

Once the concept is proven, the design is finalized, and production-intended parts are manufactured. These parts may have slightly different tolerances compared to prototypes due to manufacturing realities. This phase involves more rigorous testing, including durability testing on hydraulic servo test machines. The machines can replicate real-world driving profiles captured from various terrains, putting the shocks through hundreds of hours of simulated use to identify potential vulnerabilities.

“Even in this phase we may uncover some issues or identify some minor design iterations within that phase, and at that point we go through kind of another level of testing,” Rohde stated. “Then we start evolving our testing from concept into durability testing, both structural and performance.”

These rigorous tests can be conducted in any of our three test labs within California or Georgia due to the recent investment in all of the Fox Factory test labs. This ensures the tests meet our standards, are repeatable, keep projects on time, and leverage the years of experience across the company.

Production Phase

Finally, the shocks are built on the assembly line using production parts. These shocks undergo many of the same tests conducted in the development phase to ensure quality control.

“Our teams jumped in during production of a new product to identify and root cause an issue that arose after the start of production,” Rohde recounted. “We were able to replicate the issue on our dyno and replicate a test to find a speedy solution. It was all hands-on deck to deliver the right fix and meet shipping deadlines. I have a killer team that was able to make it all happen.”

Future of Testing

Rather than resting on their laurels, the test team is looking to adapt and get ahead of the ever-evolving landscape of vehicle technology. Rohde envisions all the test labs incorporating chassis testing into the process. This would expand in-house testing and assessment capabilities to show a bigger picture of the suspension and chassis system. This provides greater insight during the design and testing of future products, resulting in smoother rides and more control for the driver. This forward-thinking approach is a part of the Fox DNA, pushing innovation to deliver performance and elevate the overall ride experience.

Editor's Note: This is the 50th anniversary of our founder, Bob Fox, developing FOX Air Shox. Be on the lookout for more stories highlighting the people behind the products who helped push potential further.