Magnetorheological (MR) dampers have attracted the interest of suspension designers and researchers because of their variable damping feature, mechanical simplicity, robustness, low power consumption and fast response. This study deals with the optimal configuration of an MR damper using the Taguchi experimental design approach. The optimal solutions of the MR damper are evaluated for the maximum dynamic range and the maximum damper force separately. The MR dampers are constrained in a cylindrical container defined by radius and height. The optimal damper configurations obtained from this study are fabricated and tested for verification. The verification tests show that the dampers provide the specified damper force and dynamic range.