Busbar manufacture

Precision-Engineered Copper and Aluminium Busbars

H V Wooding is a leading Busbar Manufacturer UK, specialising in precision-engineered copper and aluminium busbars for 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.

Trusted by leading OEMs and energy innovators, H V Wooding delivers precision busbar solutions from prototype to volume production — supporting applications across power electronics, automotive, and renewable energy.

Busbar Manufacturer UK — Precision Busbar Solutions:

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.

Leading busbar suppliers

As one of the UK’s leading busbar suppliers and manufacturers, H V Wooding provides precision-engineered copper busbars and aluminium busbars for customers across energy, EV, and industrial sectors. Our in-house tooling, punching, and forming ensure each busbar meets exact electrical and mechanical specifications. Whether you require prototype development, repeat volume production, or coated and plated busbar assemblies, we deliver dependable supply, technical expertise, and ISO-certified quality. Partnering with H V Wooding means working with a trusted British manufacturer that combines precision engineering with responsive customer service and on-time delivery.

Copper Busbars — Strength, Conductivity and Reliability

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 — Lightweight and Efficient

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.

Flexible Busbars — Vibration-Resistant Conductors

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.

Insulation and Finishing Options

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.

Why Choose H V Wooding for Busbar Manufacture?

Choosing H V Wooding means working with a UK manufacturer that controls every stage of production in-house — from laser cutting and CNC machining through to forming, insulation, and finishing. Our engineering team supports design for manufacturability, helping customers reduce assembly time and improve electrical efficiency. We work collaboratively with OEMs, R&D teams and prototype engineers, ensuring every busbar meets the exact performance and safety standards required for high-voltage environments. Clients benefit from short lead times, competitive pricing, and a technical partner who delivers dependable results project after project.

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

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Case studies

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.

Hybrid Drivetrain – Flywheel Energy Storage Technology

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 – 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.

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