This project showcases the design and analysis of a rear stabilizer (sway) bar for the Polaris RZR Pro R 4 Ultimate, completed within a two-week development window using only rear shock displacement data and limited suspension geometry. From this minimal input, the full suspension kinematics were derived to translate real-world wheel motion into stabilizer bar torsion. To efficiently evaluate the design space, a custom analysis script was developed to automate calculations and iterate across multiple materials and configurations. This allowed for rapid comparison of performance, durability, and cost,leading to a fully defined, manufacturable solution rather than just a theoretical design. 

The final design utilizes AISI 9255 quenched and tempered spring steel, selected from a range of evaluated materials for its optimal balance of strength, fatigue resistance, and cost. The resulting stabilizer bar exceeds the required durability target of 500 operating hours, achieving a predicted life of approximately 1200 hours, while also meeting stiffness requirements for vehicle handling performance . The motion simulation on the right was developed to highlight how real suspension inputs drive components. It also allowed for simulated suspension angular behavior to check analytical calculations.