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Cost Reduction and Design Optimisation for MAST Upgrade

Project overview

The UK Atomic Energy Authority (UKAEA), a government research organisation leading the development of nuclear fusion power, required the manufacture of precision-engineered busbars for the MAST (Mega Amp Spherical Tokamak) Upgrade project. H V Wooding was selected to deliver a cost-effective, high-quality solution that met stringent performance and traceability standards.

Challenge

The initial busbar design was complex and costly, involving multiple copper and aluminium variants with numerous component types and material sizes. The project demanded tight tolerances, full material traceability, and rigorous quality assurance processes — all within strict time and budget constraints.

Solution

H V Wooding collaborated closely with UKAEA to agree on the technical requirements and project scope before supplying prototype samples of both copper and aluminium busbars. The design and material specifications were then standardised to optimise efficiency and simplify production. Through a project-managed approach, material utilisation was maximised, and flexible busbars were developed and produced to streamline assembly and improve long-term serviceability.

Results

The revised design delivered immediate cost savings while maintaining full compliance with UKAEA’s demanding quality standards. By introducing flexible busbars, assembly time was significantly reduced, and material consistency was achieved across the project. The entire scope was completed within agreed lead times and budget.

Added Value

H V Wooding reduced the overall cost of the busbar systems by between 40% and 60%, delivering substantial long-term savings through the standardisation of parts and materials. The collaboration also provided UKAEA with valuable technical support and manufacturing insight, resulting in a more efficient and sustainable design for future applications.

Trusted by Leading Brands

H V Wooding is a trusted manufacturing partner to organisations operating in advanced engineering and clean energy sectors. Our clients include world-class names such as Schneider Electric, Honeywell, Rolls-Royce, GE Renewables, and CERN, who rely on our precision, innovation, and commitment to quality.

Commitment to Quality

Certified to ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018, H V Wooding applies the highest standards of manufacturing control and traceability. Our in-house Buffer Management System, advanced metrology capabilities, and continuous investment in LEAN and FMEA processes ensure reliable performance, accuracy, and ongoing improvement across all precision busbar and component projects.

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.

Data Centres

Supporting our customers manufacturing world class products in the Data Centre sector, producing Busbars for switchboards, distribution boards, battery banks and IT infrastructure solutions.

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.

Electrical Switchgear Manufacturing Solutions

Supporting our customers manufacturing world class products in the Electrical Switchgear, Power Generation and Power Distribution markets.

Renewable Energy

Busbars, laminations and assemblies for wind, solar and tidal energy. H V Wooding supplies GE, Vestas and Siemens with precision renewable components from design to volume production.

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.

Medical & Surgical

From providing life critical, high volume, pressed Medical ventilator heater plates, to complex Titanium Spinal Implants, to Cancer probe Electrodes, we offer over 50 years of experience supplying to a wide, diverse range of customers in the Medical sector.

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.

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