There’s no doubt – electric vehicles (EVs) are reshaping the automotive landscape. As the demand for traditional ICE components steadily declines, new challenges are emerging. Among them, steering and suspension systems are taking on a more vital role than ever before.
Generally, EVs weigh more than internal combustion engine (ICE) vehicles – on average, up to 25% more. This difference depends on several factors including battery size, platform design and vehicle class. However, the primary contributor is the battery pack, which can add several hundred kilograms to the vehicle’s total weight.
Inevitably, this added weight places increased stress on key vehicle systems, particularly steering and suspension components, as these systems must now work harder to manage greater loads whilst still being able to deliver a smooth, responsive ride with precise handling. This challenge is further heightened by the altered weight distribution in electric vehicles, most of which typically feature a lower centre of gravity due to a lower mounted battery pack. This alters the vehicle’s dynamic behaviour, influencing factors such as pitch, roll and cornering response. As a result, EVs require robust, high-performance suspension solutions that can withstand the added strain and support the vehicle’s dynamic behaviour without compromising on safety or comfort. It’s precisely these characteristics – higher weight and altered dynamics – that are reshaping the requirements for steering and suspension technologies across the automotive industry.
To meet these heightened demands, OE manufacturers like KYB are adapting their product by developing advanced suspension components specifically engineered for the increased weight and unique dynamics of EVs. In support of this, KYB operates a vast global R&D network, complemented by dedicated technical centres where innovative materials and technologies are continuously tested and refined. The push to reduce the weight of EVs, for instance, is already influencing material choices; KYB is exploring high-strength composite spring seats, which can save up to 0.5 kg per strut without compromising performance.
When it comes to developing suspension for vehicle manufacturers, KYB has already seen an increased demand for active suspension systems rather than traditional, passive systems. In passive suspension systems, damping characteristics – such as compression and rebound rates – must be fixed during the vehicle development phase. In contrast, active suspension systems allow for real-time adjustment of damping forces. By using sensors to read the road, active suspension systems can dynamically adjust damping in real time based on various factors such as road conditions, steering angle and acceleration. This not only allows for optimised ride comfort but is also instrumental in helping to manage any extra weight.
In recent years, KYB has worked on a number of projects with leading vehicle manufacturers to develop active suspension solutions. For example, in 2024, KYB’s electronically controlled shock absorbers were adopted by the Volkswagen Group for vehicles equipped with the DCC Pro (Dynamic Chassis Control Pro) system, including the Tiguan, Passat Variant, SKODA Superb and Kodiaq. This collaboration highlights KYB’s expertise in precision damping technologies and its ongoing commitment to develop product based on the demands of the market.
If we look further into the future – as autonomous driving features advance – the need for active suspension will no longer be a luxury, but a complete necessity. In order to operate as a hands-free vehicle, these vehicles rely solely upon sensors such as cameras, LiDAR and ultrasonic sensors to read and interpret the environment around them. An ineffective suspension system can cause vibration and jolts, reducing the accuracy of these sensors and as such, any compromise of their efficacy can become safety critical. In these circumstances, active suspension will help to isolate the vehicle body and its sensors from any imperfections on the road.
“We’re already beginning to see an increased demand for parts as these vehicles enter the Aftermarket and that’s only going to increase over time”, says Jordan Day, Senior Marketing Manager at KYB Europe. “KYB has been at the heart of electric vehicle development from the very beginning – serving as OE supplier for the first mass-produced EV (Toyota Prius) – and that heritage is reflected in the strength of our EV and HEV offerings. In fact, when compared with 2024, the number of part numbers KYB has listed for EV and HEVs has more than tripled in 2025 alone and we’re seeing an increased number of parts introduced in the range for Tesla, Polestar and other popular EVs”. As this advanced OE technology arrives in the aftermarket, it’s more important than ever that workshops fit genuine, OE specification components. The growing complexity of suspension and steering technologies means that using lower-quality components carries significant risk. To aid this transition, KYB trainers and technical support will be on hand, ensuring that workshops have the skills and expertise required to fit and calibrate these suspension systems reliably and safely.