Project Overview
A global manufacturer in the renewable energy sector was developing the next generation of tidal turbines and required a partner to support both the design and manufacture of laminate sections for the Permanent Magnet Generator (PMG). H V Wooding Ltd was selected to provide an integrated engineering and manufacturing solution that would optimise performance, reduce costs, and validate the concept ahead of full production.
Challenge
The laminate sections were highly complex and difficult to manufacture to the required tolerances. The original design was inherently expensive and required multiple manufacturing processes for individual parts and assemblies. The customer also needed to prove the design concept prior to production, ensuring it was both technically and commercially viable before large-scale investment.
Solution
H V Wooding engaged in an early design review with the customer and proposed an alternative approach to improve manufacturability and reduce costs. A wire-eroded prototype was produced for evaluation and testing, allowing the design to be validated quickly. Quality requirements for all sub-components and assemblies were clearly defined, and a fully integrated manufacturing route was implemented — including tooling, stamping, CNC machining, special-purpose machinery, and assembly. H V Wooding also managed the external supply chain for shot blasting and painting, providing a complete end-to-end solution.
Results
The collaboration enabled the customer to optimise the design technically and commercially, achieving greater performance and manufacturability. By consolidating multiple processes under one supplier, H V Wooding streamlined production, managed all subcontract operations, and delivered a robust, repeatable manufacturing solution capable of meeting demanding quality and performance criteria.
Added Value
The project achieved a 25% cost reduction through improved design and manufacturing processes for the laminate sections. The simplified, single-source supply chain reduced complexity and administration while improving delivery reliability. Product reliability and overall performance were significantly enhanced, creating new business opportunities and supporting the customer’s continued growth in the renewable energy sector.
Trusted by Leading Brands
H V Wooding partners with world-class organisations in the renewable energy, electrical, and advanced engineering industries. Clients including GE Renewables, Schneider Electric, Honeywell, Rolls-Royce, and CERN trust us to deliver precision-engineered solutions that drive innovation and efficiency.
Commitment to Quality
Accredited to ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018, H V Wooding ensures the highest levels of quality, consistency, and environmental responsibility. Our advanced Buffer Management System, precision metrology capabilities, and adherence to LEAN and FMEA principles underpin our ability to deliver reliable, high-performance components for complex renewable energy applications.
