A suspension bar for a hanging file having coplanar longitudinal top and bottom portions and a longitudinal middle portion having an offset parallel to the coplanar longitudinal top and bottom portions. A traverse perimeter flare is around each notch. A plurality of small depressed sections in the longitudinal middle portion are expanded to prevent nesting of stacked suspension bars. The notches of the suspension bars are coated to reduce friction. Sheet metal stock need be only half the thickness of conventional flat suspension bar stock with the same load-supporting capacity when incorporated in a hanging file folder thereby lowering manufacturing cost of suspension bars and hanging file folders. This invention also includes a process for making the suspension bars and for installing the suspension bars in jackets at a high production rate, including automated production lines.