The suspension system is a significant component in the automotive industry. However, its design and manufacturing still face some challenges high cost, complex control algorithms, and improving system efficiency. Therefore, the current study attempts to propose a robust design to solve some issues concerned with the suspension system. The final design was preceded by a conceptual one to adjust some design parameters towards achieving the targeted goal. Some consideration was taken during the design stage like weight, cost, durability, efficiency, load capacity, size, and materials selection. The design was examined based on two factors: operational stress analysis and system estimated cost. Based on the archived results, the design is considered to it satisfy the proposed objectives. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2025.