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Car air suspension is a vehicle suspension system in which the elastic element is a gas-filled air spring that supports static load and provides ride-height compliance by varying internal pressure, with ancillary pneumatic and electromechanical components to supply, meter, and retain compressed air; architectures include air springs mounted separate from the damper or combined as an air strut around a shock absorber. Core materials include multilayer elastomer–cord bellows for rolling-lobe or convoluted air springs, typically chlorobutyl or EPDM inner liners with nylon/polyester cord reinforcement and outer protective rubber, steel or aluminum bead plates and pistons (or injection-molded engineering thermoplastics) for end closures and bearing surfaces, copper conductors and sealed polymer connectors for wiring, nylon (PA11/PA12) air lines with brass or composite push-to-connect fittings, valve/manifold bodies in aluminum or polymer with stainless steel or brass internals, compressors using die-cast aluminum housings with steel crank mechanisms and PTFE-based piston rings, desiccant dryers (silica gel or molecular sieve), steel or aluminum air reservoirs, and position sensors (potentiometric, Hall-effect, or ultrasonic) for height feedback. By control type, manual systems use mechanically linked height control valves to charge or exhaust air based on axle motion, establishing load-leveling without electronic feedback; electronic systems employ an ECU that interprets height sensor signals and drives a compressor, solenoid valve block, and exhaust to regulate each axle or corner, integrate self-leveling and kneel/raise functions, and coordinate with chassis networks, with residual-pressure and check valves providing fail-safe retention. Manufacturing of air springs comprises rubber compounding, calendering and bias-angle setting of cord fabrics, inner-liner and cover preparation, ply layup on mandrels, splice formation, bead wire placement, curing/vulcanization in molds to define rolling geometry, leak and burst testing, and crimping or rolling attachment to bead plates and pistons; compressors are produced by machining or die casting housings, assembling DC motors, crank–piston groups, reed or plate valves, integrating dryers and pressure/temperature sensors, followed by end-of-line flow and duty-cycle characterization; valve blocks are machined or molded manifolds populated with proportional or on/off solenoids and pressure transducers, then helium or pressure-decay leak tested; final assembly integrates reservoirs and pneumatic lines, mounts air springs or struts to the chassis with bushings and dampers, routes the harness, and performs calibration of static heights, closed-loop checks, and system-tightness verification under specified pressure and temperature conditions.
