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01303 264471 sales@hvwooding.co.uk

Busbar manufacture

H V Wooding is a leading UK manufacturer of copper and aluminium busbars, supplying energy, rail, automotive and renewable sectors. From high-voltage switchgear to advanced EV and hybrid battery systems, our precision-engineered busbars are trusted worldwide for performance and reliability. With over 50 years of expertise, we support both large-scale production and specialised low-volume projects, delivering repeatable quality every time.

Our capabilities

We manufacture busbars to specification down to 0.3mm in copper and 0.5mm in aluminium. Applications range from polyolefin and PVC-insulated busbars for 11KVA switchgear, through to complex EV and hybrid battery busbars coated with advanced insulation materials such as Resicoat HGF03R (red/orange) and Nylon BB, achieving dielectric ratings between 1.5KV and 5KV.

Copper busbars offer outstanding conductivity, durability and resistance to fatigue, short circuits and environmental factors, making them the preferred material where reliability is critical. Our advanced EHRT punching and forming machines allow fast, accurate production of copper busbars for industries including switchgear, control panels, EV systems and renewable energy.

Aluminium busbars are ideal where weight saving is a priority. H V Wooding has produced millions of aluminium busbars for applications in power conversion, marine, aerospace and transformers, combining strength, efficiency and weight reduction.

We also manufacture flexible busbars using a proprietary endless-loop system, creating vibration-resistant, high-capacity conductors. Produced from thin, compressed copper, they deliver durability while maintaining the ability to flex under load.

To meet demanding application needs, we provide a wide range of finishes and insulation services. Options include powder coating, epoxy coating, heat-shrink sleeving and electroplating in tin, silver and nickel. These finishes support critical EV and high-voltage applications, where electrical integrity and long-term performance are essential.

Looking for a reliable busbar manufacturer in the UK? Get in touch to discuss your requirements.

📞 +44 (0)1303 264471
📧 sales@hvwooding.co.uk

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Case studies

Strategic outsourcing partner

A leading international manufacturer of electrical accessories were producing all components in house. In order to focus on core activities and increase profitability, they needed a strategic outsourcing partner that they could trust. After a detailed evaluation, they decided to outsource all presswork components to HV Wooding.

High Volume of Metal Stampings and Busbars

A leading Global manufacturer of Electrical Automation and Control Solutions have a high volume of Metal Stampings and Busbars used within their product groups. These include regular repeat items and also spot ordered parts that are delivered to multiple locations.

Looking to reduce the cost of manufacture

UK Atomic Energy Authority is a UK government research organisation responsible for the development of nuclear fusion power. Requirement to manufacture Busbars for MAST upgrade.

Science & Research - CERN

A twin-aperture, 10 m long, prototype magnet was designed by CERN to gain experience in the construction of full scale twin-aperture Dipole Magnets. HV Wooding were given the task to produce the Twin-aperture Dipole magnet Laminations. Click to read a Case study demonstrating our ongoing work with CERN on the Large Hadron Collider - and the positive impact from our input.

Data Centre Busbars

A Global Social Media Platform were looking to enhance the performance, reliability and efficiency of their Data Centre Operation. This project involved HV Wooding in the design optimisation and manufacture of Busbars.

Next generation of Tidal Turbines

A Global manufacture in the “Renewables Sector” are developing the next generation of Tidal Turbines. In order to optimise engineering performance they needed a partner to help facilitate both the design and manufacturing solution of “Laminate Sections” for the Permanent Magnet Generator.

Next Generation of Offshore Wind Turbines

A worldwide manufacturer of Wind Turbines, developing the Generator Busbars for the next generation of offshore 7MW machines.

“Hybrid Drivetrain” for Motorsport and Transportation applications

A Global manufacturer of “Hybrid Drivetrain” for Motorsport and Transportation applications. A key market for flywheel energy storage technology is the public transport sector. This technology can save fuel and reduce green house gas emissions by up to 30% in a city bus for example.

Ventilator Challenge UK

British engineering firms were called on to switch to making medical ventilators as concern grew about the effects of the coronavirus pandemic.  This follows an appeal by Boris Johnson, who held an emergency conference appealing for an urgent effort to address the national shortage.

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Related articles and news

Exhibitions 2025/2026

We have a very busy exhibitions and conference calendar for 2025, meeting existing clients and introducing ourselves to new contacts, and learning more about the industries we serve. Exhibitions include: The Battery Show, Future Propulsion Conference, Battery Tech Expo, Cenex Expo, NVN Forum, SMMT Connected, Power Transmission & Technology Expo & Advanced Engineering.

Success in Busbar coating project with Nuclear AMRC & University of Sheffield

The project, supported by Innovate UK through the Faraday Battery Challenge, aimed to develop a new powder coating process to improve the quality and performance of busbars for the fast-growing electric vehicle market. "The results have allowed us to better understand the relationship between the dielectric strength of the busbar and the coating thickness produced by the processes investigated."

HV Wooding Unveils Comprehensive Brochure

We are excited to reveal our new brochure highlighting core capabilities in wire erosion, laser cutting, presswork & tooling, powder coating, and electroplating. The brochure offers an in-depth look into the intricate processes involved in crafting busbars, core packs, and precision components.

Investing in Quality

To assist the constantly evolving challenges that face our highly experienced quality team at H V Wooding, we have recently invested in the super accurate Trimos height gauge and the Vision inspection system ‘InspecVision Planer’ for fast and accurate measurement of multiple parts.

JOSCAR Accreditation

The JOSCAR Registration Mark is valued by some of the largest purchasers in the defence community and indicates that our organisation has gone through the process required to demonstrate its commitment and credentials to the industry.

Electric Vehicle boost for HVW

Having been given a glimpse of a potential future should we make the switch to Electric Vehicles - with less air pollution and improved air quality being documented during the COVID-19 lockdown - more buyers are realising the benefits of moving away from petrol and diesel cars.
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