Powder Coated Busbars
At H V Wooding Ltd, we manufacture powder coated busbars for electric vehicles, hybrids, and advanced energy systems. From prototypes to mid-volume production, we combine precision engineering with robust insulation to deliver reliability where it matters most.
Why powder coating matters – As EV voltages rise, insulation is critical. Powder coating provides a tough dielectric layer that protects against electrical stress and mechanical handling. Unlike paint, it is a safety-critical coating. Even a single pinhole can cause partial discharge and long-term failure.
To prevent this, every busbar we produce is subject to holiday testing, a non-destructive process that identifies defects and ensures coating integrity before parts leave our factory.
Precision Manufacturing – Busbars must meet exact tolerances to fit modern EV battery packs and power systems. At H V Wooding, we ensure accuracy at every stage. Bends and radii are formed precisely to prevent clearance issues and reduce stress during assembly. Edges and surfaces are finished to support reliable powder coating adhesion, while flatness is carefully controlled to maintain consistent fit. Every batch is produced to the same dimensional standard, ensuring repeatability and reducing the risk of vibration wear once in service.
We use advanced processes such as laser cutting, CNC machining, forming, and electroplating to manufacture complex busbars quickly and accurately, supporting projects from prototype through to mid-volume production.
Quality Assurance – Defects in a busbar can have costly consequences once sealed in a battery pack. Our quality assurance process is designed to catch problems early. Dimensional checks confirm accuracy and repeatability. Coating inspections verify insulation integrity, while electroplated surfaces are tested for adhesion and consistency.
As our Technical Manager, Simon Stewart, explains: “Powder coating isn’t paint — it’s a safety-critical dielectric”.
Working with Engineers – We collaborate closely with design engineers to make busbars manufacturable without compromising performance. Small adjustments at the design stage, such as optimising bend radii or allowing clearance for coatings, save time and cost later while ensuring reliable results.
Why choose H V Wooding – With over 50 years of precision manufacturing expertise, we have a proven track record across EV, marine, and high-performance sectors. Our flexible approach supports projects from prototype to mid-volume production. Based in the UK, we supply customers worldwide with high-quality, holiday-tested busbars that deliver reliability in the most demanding applications.
Contact Us
Looking for a reliable partner to manufacture powder coated busbars for your EV or energy project?
📞 Call us on +44 (0)1303 264471
📧 Email sales@hvwooding.co.uk
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To explore how we could make a difference to your organisation, contact us for a free assessment of potential opportunities.