Frontal Protection

Vital for rural and remote area travel, ARB frontal protection will provide substantially improved protection for vulnerable mechanical components against animal strikes whilst providing a solid base for mounting other accessories like driving lights, winches and CB antennas.

ARB’s bars are superbly engineered and manufactured not only to maintain maximum functionality but also to ensure they complement the look of the vehicle.


Engineering a bull bar requires careful consideration of many factors to ensure it adequately serves its purpose. Factors such as vehicle design, crush rate, air bag deployment, approach angles, accessory fitment, strength, weight and aesthetics are incorporated into every ARB bar before it enters production.


ARB has invested heavily on vehicle crash barrier testing to validate the performance and compliance of our air bag compatible bull bars. To ensure compatibility, ARB assesses each vehicle’s frontal crush characteristics and replicates the crush rate in the design of each air bag compatible bull bar and mounting system. Using this method ensures that the vehicle’s crush rate and air bag triggering are not altered when a bull bar is installed.

Laser Cutting

Every bull bar starts off as a flat sheet of steel. The components are cut into shape using ARB’s in-house laser cutters, which produce highly accurate cuts to within 0.2mm, without any heat distortion. This process results in 100% accuracy, which is maintained throughout the entire fabrication of the bar.

Metal Forming

Using traditional forming in a multi-axis brake press, as well as more advanced press forming where intricate shapes are required, flat sheets of steel are folded to make up each section of the bull bar. Computer Numerically Controlled (CNC) machines are used to ensure maximum accuracy and consistency, while aRB’s multi-fold design, used in most of our bull bars, provides optimal strength.

Tube Work

ARB’s bull bars are manufactured with strong 2.6mm wall thickness tubing. The tube is cut to the desired length and bent with a CNC Eagle internal mandrel bender, ensuring consistency and even wall thickness across all sections.

Robot Welding

Subsequent to being folded into shape, each section is welded utilising a robot welder. Robot welders are used for straightforward, repetitive welding jobs that require speed and accuracy.


When individual components are complete, the bull bar is assembled. All sections – pan, wings, uprights, the outer frame and chassis brackets – are placed in a jig and tack welded. This is followed by finish welding for strength and aesthetics.

Post assembly

To complete the manufacturing process all ARB bars are shot blasted, before entering a 5 stage chemical was to prepare the surface for maximum powder adhesion. They’re then powder coated and oven baked. This is not only an attractive and durable finish; it provides an excellent base for painting if colour coding is required.

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