Skip to content
Open Menu Close Menu

Hybrid Drivetrain – Flywheel Energy Storage Technology

Project Overview

A global manufacturer of hybrid drivetrain systems for the motorsport and transportation industries partnered with H V Wooding Ltd to support the development of advanced flywheel energy storage technology. This innovative solution enables significant fuel savings and reduces greenhouse gas emissions by up to 30% in public transport vehicles such as city buses, contributing to a more sustainable and energy-efficient future.

Challenge

The project required the design and manufacture of tooling for laminations made from 0.1mm electrical steel, with exceptionally tight tolerances of below 30 microns. The customer needed prototype solutions that could transition seamlessly into volume production, ensuring both scalability and quality. Additional challenges included achieving a burr-free stamping process and establishing a reliable material supply chain for this specialist grade of steel.

Solution

H V Wooding developed a bespoke supply chain to source the required raw materials and worked closely with the customer to finalise the geometry of the lamination profile. Prototype samples were produced via wire erosion, enabling detailed testing and validation. The team then designed and manufactured complex compound tooling for full-scale production, incorporating a custom catcher unit to safely remove parts from the tool. In-process inspection was carried out using a dedicated CMM programme to ensure consistent accuracy and quality at every stage.

Results

The collaboration delivered high-quality laminations that met all technical specifications and performance expectations. H V Wooding developed a cost-effective and repeatable production process, establishing a secure material supply chain where none had previously existed. The customer received the first laminations of their kind for this application, supporting both prototype validation and future production planning.

Added Value

The project provided the customer with a clear competitive advantage in hybrid drivetrain and flywheel energy storage technology. H V Wooding’s innovative tooling and process design optimised future product scalability and created a robust manufacturing platform for next-generation systems. Additionally, by leveraging its extensive industry network, H V Wooding helped to enhance the customer’s supply chain, introducing complementary partners who added further value to the overall project.

Trusted by Leading Brands

H V Wooding is a trusted manufacturing partner to global leaders in the automotive, motorsport, renewable energy, and engineering sectors. Clients including Rolls-Royce, Schneider Electric, Honeywell, GE Renewables, and CERN rely on our precision manufacturing expertise, technical innovation, and long-term partnership approach.

Commitment to Quality

Certified to ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018, H V Wooding operates to the highest standards of quality and environmental responsibility. Our Buffer Management System, advanced metrology, and LEAN manufacturing processes ensure consistent precision, process traceability, and delivery excellence for every project.

Laser Cutting

H V Wooding provides precision laser cutting services in copper, aluminium, and electrical steels for laminations, busbars, and complex components. We deliver fast-turnaround prototyping and mid-volume production with tight tolerances and clean edges.

Wire Erosion

H V Wooding provides precision wire erosion (EDM) services with tolerances down to ±5 microns. We manufacture components for the aerospace, EV, medical and research sectors, offering exceptional accuracy, clean finishes and rapid turnaround.

Presswork & Tooling

H V Wooding designs and manufactures precision press tools and provides high-quality presswork for a range of industries. Our in-house toolroom ensures fast turnaround, consistent quality and cost-effective solutions from prototype to volume production.

Busbar Manufacture

H V Wooding designs and manufactures precision copper, aluminium and flexible busbars for power, EV and renewable energy systems, with full insulation and finishing options.

Powder Coating

Powder coated busbars for EV, hybrid and energy systems. UK-made with holiday-tested insulation, precise fit and over 50 years’ precision manufacturing expertise.

Motor Stator/ Laminations

H V Wooding produces precision electrical steel laminations using laser cutting, wire erosion and press tooling. We support prototyping through to series production for magnetic assemblies, motors, transformers and research applications.

Electroplating

In-house electroplating in tin, zinc, nickel and silver. Rack and barrel options, with lab and X-ray testing to ensure coating accuracy, durability and quality.

Assembly

Mechanical, busbar and general sub-assembly services. Welding, fitting, packaging and line-side delivery with ISO-certified quality and cost-effective outsourcing from H V Wooding.

Electric & Hybrid Vehicle

UK manufacturer of busbars, motor laminations and core packs for hybrid and electric vehicles. Prototype to mid-volume production with precision processes including wire EDM, laser cutting and stamping.

Motorsport & Niche Vehicles

H V Wooding are experts in the provision of manufacturing services to the high end Motorsport, F1 and Niche vehicle market including the manufacture of bespoke Busbars for battery and drivetrain applications.

Electric Motors

Adding value to our customers by optimising the design and manufacturing of complex Motor Laminations and Core Packs. Our core activity in this arena is focused around demanding and complex high end motor applications where we are able to offer customers years of experience in working with a wide range of materials and complex geometries to achieve the demands of the new generation industries.

Science & Research

We have gained a solid reputation for the supply of magnet assembly low carbon steel Yokes and stainless steel Collar laminations for prototype and upgrades to the Hadron Collider. Customers include; CERN, CEA, Elytt and Brookhaven.

More projects

Strategic Outsourcing Partner for Electrical Components

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 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.

Cost Reduction and Design Optimisation for MAST Upgrade

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.

Precision Laminations for CERN’s Twin-Aperture Dipole Magnet

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 for a Global Social Media Platform

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 Tidal Turbines – Laminate Sections for a Permanent Magnet Generator

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 Offshore Wind Turbines – 7MW Busbar Systems

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

Ventilator Challenge UK – Rapid Response Manufacturing for Critical Components

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.

Main case studies page