FAQ
WIRE EROSION
What is wire erosion?
Wire erosion (also called wire EDM) is a precision process that uses a thin wire and electrical sparks to cut metals with exceptional accuracy. It’s ideal for aerospace, tooling, medical, and scientific components.
What tolerances can wire erosion achieve?
Our wire erosion machines achieve tolerances down to ±5 microns, making them perfect for high-performance applications.
Who are wire erosion / wire edm suppliers in the UK
HV Wooding are the UK’s leading wire erosion supplier, offering decades of experience in the sector. We offer tight tolerances and fast turnaround.
What materials can be cut with wire erosion?
Wire erosion works with conductive metals such as steel, titanium, and specialist alloys.
How does wire erosion compare to laser cutting?
Wire erosion provides greater accuracy and finer detail than laser cutting. While laser cutting is faster for high volumes, wire EDM is best for intricate shapes and tight tolerances.
Why choose H V Wooding for wire erosion?
We have decades of EDM experience, advanced machinery, and proven results supplying industries from aerospace to scientific research, including CERN projects.
BUSBARS & ELECTRICAL COMPONENTS
What is a busbar?
Busbars are conductive components that distribute power in vehicles, batteries, and industrial systems. They improve reliability, reduce resistance, and enhance safety.
Where can I find custom busbar manufacturing services near me?
H V Wooding manufactures busbars from prototype to volume, and offers in-house electroplating and powder coating services.
What’s the difference between powder coating and electroplating busbars?
- Powder coating provides durable insulation and colour coding.
- Electroplating enhances conductivity and corrosion resistance.
Why choose custom or plated busbars?
Custom busbars are engineered to meet specific electrical, thermal, and spatial requirements. By tailoring the design, they improve efficiency, reliability, and ease of assembly within your system.
Plated busbars — such as tin, nickel, or silver plated copper — provide additional advantages, including:
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Improved surface conductivity
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Enhanced corrosion resistance
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Extended service life in demanding conditions
These benefits make plated busbars particularly valuable in EV battery systems, renewable energy applications, data centres, and other environments where performance and durability are critical.
What is the role of busbars in modern power systems?
Busbars are a core element in modern power management, simplifying electrical distribution while improving safety and reducing energy losses.
From EV battery assemblies and control panels to industrial energy systems, the right busbar material — whether aluminium, copper, or a flexible laminated design — can significantly affect performance.
When specifying a busbar, it’s important to consider factors such as material selection, coating, and form to achieve the best electrical and thermal characteristics for your application.
Can you get an electric shock from a powder coated busbar?
Powder coating is designed to insulate busbars and prevent electric shock — but its safety depends entirely on the integrity of the coating and the voltage of the system.
When applied correctly, powder coating forms a continuous dielectric barrier that prevents contact with live conductors and protects against short circuits. It also provides durable resistance to moisture, corrosion, and mechanical wear, helping maintain insulation over time.
However, even a microscopic defect — such as a pinhole, thin area, or damaged spot — can compromise the insulation. In high-voltage environments, this can lead to partial discharge or, in the worst case, an electric shock or electrocution if the busbar is live.
That’s why integrity testing is critical. At H V Wooding, every powder-coated busbar undergoes holiday testing and visual inspection to ensure a fully intact coating, giving customers complete confidence in the electrical safety and performance of their assemblies.
Types of busbars – choosing the right one.
Different applications demand different busbar types. Below is a summary of the most common options and their uses:
Flexible Copper Busbar
Constructed from layered copper foils, these are ideal for compact or vibration-sensitive installations where flexibility and current flow are both essential.
Aluminium Busbar
Lightweight and cost-effective, aluminium busbars are widely used in large-scale power distribution and renewable energy systems.
Nickel-Plated Copper Busbar
Highly resistant to corrosion, making it suitable for marine, industrial, and outdoor applications.
Tin-Plated Copper Busbar
Combines high conductivity with excellent oxidation resistance. A reliable choice for switchgear and electrical control panels.
Silver-Plated Copper Busbar
Provides outstanding conductivity and stability, particularly valuable in high-performance or precision electronic systems.
Custom Busbars
Designed to meet unique mechanical or electrical requirements. Commonly specified in automotive, aerospace, and robotics applications.
Copper Battery Busbar
Used in lithium-ion battery packs to connect cells and equalise current flow across the system.
Flexible Busbar
Designed for dynamic or space-restricted electrical systems where movement or vibration is a factor.
How to use busbars in practical applications
Effective busbar integration starts with selecting the right material and dimensions for your system:
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Choose material and plating based on the current rating and environment — for example, nickel-plated copper is preferred for corrosion-prone settings.
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Determine size and profile to match current-carrying and heat-dissipation needs.
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Connect components such as fuses, circuit breakers, or batteries directly via terminals or clamps.
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Ensure proper insulation, spacing, and fixing to maintain electrical safety and compliance.
H V Wooding designs and manufactures custom busbars and precision-machined components to suit all these applications, from prototype development through to volume production.
Do you supply busbars for electric vehicles?
Yes — we manufacture high-voltage EV busbars for cars, trucks, and buses, helping power the future of clean transport.
Can you provide prototype busbars?
Yes — we supply prototype busbars for R&D projects, then scale up to mid- and high-volume production
CAPABILITIES & SERVICES
Do you offer prototype manufacturing?
We support customers from prototype development through to full production runs, reducing the need to change suppliers as projects grow.
What finishing services do you provide?
We offer powder coating, electroplating, heat treatment, assembly, and packaging — ensuring components are delivered production-ready.
Can H V Wooding supply to tight lead times?
Yes — we have flexible scheduling to meet urgent deadlines without compromising on quality.
INDUSTRIES SERVED
What industries do you supply?
We work with aerospace, defence, automotive, renewable energy, electric vehicles, and research institutions.
Do you supply aerospace and defence components?
Yes — we manufacture high-reliability aerospace and defence parts with full traceability and tight tolerances.
Do you export internationally?
Yes — we export across Europe and globally, supplying leaders in EV, energy, aerospace, and science.
Have you supplied scientific research projects?
Yes — we supplied laminations for CERN’s dipole magnets, produced to 4–8 micron tolerances.
GENERAL & TRUST
How long has H V Wooding been established?
We were founded in 1967, bringing over 50 years of precision manufacturing expertise.
Where are you based?
We are based in Hythe, Kent, UK, serving customers nationwide and internationally.
What makes H V Wooding different?
Unlike many suppliers, we integrate stamping, wire erosion, CNC machining, busbar manufacture, and finishing services under one roof — reducing lead times, costs, and quality risks.