In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria.
Traditionally, Natural rubber (NR) has traditionally been favoured for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. PU's high compressibility, low lateral expansion, and low compression set make it the material of choice across automotive, aerospace, and industrial sectors. Other materials like thermoplastic elastomers (TPE/TPU) and EPDM rubber are also used, offering advantages such as recyclability, ease of processing, and high weather resistance. Silicone rubber, though less common, is selected for specialized applications requiring exceptional thermal and environmental stability. The choice of material depends on the specific application requirements—whether it’s maximizing comfort, withstanding harsh environments, reducing weight, or improving sustainability.
This study revisits NR with the goal of re-establishing its viability by enhancing its performance to match or surpass that of PU. Through compound optimization and advanced material processing techniques, significant improvements have been achieved in NR’s mechanical strength, compression set resistance, and environmental durability.
The result is a next-generation NR formulation that delivers performance comparable to PU while retaining the ecological and economic advantages of natural rubber. This research demonstrates a sustainable pathway toward high-performance elastomeric materials, bridging the gap between conventional and advanced solutions in modern engineering applications.