The systematic sub-optimal design procedure for valve-mode magnetorheological fluid (MR) dampers is proposed. The design procedure for MR dampers has been developed from considerations on optimization problems and magnetic analysis. According to the proposed design procedure, a four-stage valve-mode MR damper with the capacity of about 10 kN has been designed, manufactured and tested. The effectiveness of the proposed sub-optimal design procedure has been confirmed through a series of tests of the 10 kN MR damper using a servo-hydraulic universal testing machine.