William Hughes Group, a renowned designer and fabricator of springs and wire forms, is expanding its operations in busbar research, design, testing, and CNC fabrication following a series of successful projects last year.
The company, with a rich engineering legacy dating back to before the Industrial Revolution, is leveraging its extensive wire-forming expertise to develop complex busbar geometries from ready-insulated, reel-fed stock.
Graham Burgon, Sales Executive at William Hughes, emphasized the increasing demand for precision-engineered electrical components due to the rising prominence of battery-based systems in various global markets. He highlighted the need for OEMs and tier-one suppliers to accommodate complex real-estate limitations across sectors beyond electric vehicles, including marine, rail, and heavy industries like mining.
Traditionally, bus bars have been manufactured through stamping and bending processes, which can be costly and less flexible for altering geometries. William Hughes Group’s approach involves using advanced CNC technology to form pre-coated copper stock, preserving the insulation along the bar’s length efficiently.
Burgon explained the seamless integration of busbar fabrication with the company’s wire and spring capabilities, underscoring the similarity in techniques and processes, albeit with different cross-sectional materials. He emphasized the importance of extensive research and development to meet stringent quality and complexity standards, crucial in expanding their success within the electric vehicle and broader battery markets.
The expansion into busbar fabrication represents a strategic move by William Hughes Group to capitalize on emerging opportunities in the global mobile battery market. The company’s innovative approach promises efficient and high-quality solutions to meet evolving industry demands for sophisticated electrical components.