Electroplating & Powder Coating services
At HV Wooding, we pride ourselves on offering an in-house electroplating facility for tin, zinc, nickel, and silver. This allows us to exercise a high degree of quality control, ultimately enhancing the performance and quality of the finished product. Our electroplating facility includes both rack and barrel options to accommodate a wide range of projects.
In addition to the aesthetic benefits, our electroplating services also provide several functional advantages such as stabilizing electrical contacts, preventing corrosion, and optimizing tribology. Our experienced team is available to provide expert guidance and advice on the most suitable coating for your specific project.
Electroplating Services include:
- Tin Rack & Barrel Plating
- Silver Rack & Barrel Plating
- Zinc Rack & Barrel Plating
- Nickel Barrel Plating
At H V Wooding, we have our own laboratory for maintaining chemical plating solutions, complimented by our advanced X-ray facilities to ensure we are providing the correct dimensional and quality specifications.
Specialist Powder Coating:
Following our work with materials and engineering researchers from the Nuclear AMRC and other parts of the University of Sheffield, supported by Innovate UK through the Faraday Battery Challenge, H V Wooding have developed a new powder coating process to improve the quality and performance of electric vehicle busbars for the fast-growing market.
Project scope: Customers in the electric and hybrid vehicle market tend to specify their requirements in terms of kilovolt rating and insulation performance, not coating material or application method. Existing coating methods were difficult to control, with a high level of component rejections due to the coating specification and application failing to meet requirements. A new coating method needed to be produced, resulting in busbars with a consistent specified performance.
With the demand for busbars expected to increase significantly as road transport is electrified, an optimised and automated manufacturing process would give HV Wooding a significant competitive advantage in a rapidly expanding international market.
Our project focused on epoxy powder coatings, applied by fluidised bed or spray processes. Powder coatings are generally safer than heat shrink sleeved insulation for electric vehicle busbars, and offer better thermal and electrical performance which allow for a more compact battery design.
The Nuclear AMRC researchers designed a series of experiments to be carried out our production facility, to determine and optimise the key process variables for a variety of coating processes. The researchers also worked with us to optimise laser cutting and deburring of the metal busbar, as any surface burrs can affect the performance of the coating, and define a standardised production process from stock material to final testing.
“HV Wooding has been a great collaborative partner to work with,” says James Leatherland, the Nuclear AMRC’s programme manager for collaborative R&D projects. “It’s great to see a project that has had immediate benefits for a UK manufacturer with business wins happening before the project has concluded,” Leatherland continued. “We think this project and the investment in the automated manufacturing process will put HV Wooding into a globally competitive position in a growing and important market.”
During the one-year project, the Nuclear AMRC team drew on additional expertise from the University of Sheffield. The AMRC – like the Nuclear AMRC, part of the UK’s High Value Manufacturing Catapult – advised on how the optimised process could be automated and scaled up, and the University’s Department of Electronic and Electrical Engineering helped develop a standardised test procedure for quality assurance.
“The results have allowed us to better understand the relationship between the dielectric strength of the busbar and the coating thickness produced by the processes investigated” says Paul Allen, Business Development Director at H V Wooding. “Even before the project finished, we secured new business as a result of the improved control of the busbar coating process. This contract has allowed us to invest in a nickel electroplating production line to enhance our production capacity and capability”.
HV Wooding previously worked with the Nuclear AMRC through the Fit For Nuclear programme, which helps manufacturers meet the quality expectations of the nuclear supply chain. It is also working through the Fit For Offshore Renewables programme, a collaboration between the Nuclear AMRC and Offshore Renewable Energy Catapult.
If you have a Busbar coating requirement to discuss, please contact out team on 01303 264471 or email drawings to firstname.lastname@example.org
Science & Research - CERN
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.
Ventilator Challenge UK
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.
Next generation of Tidal Turbines
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.
High Volume of 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.
“Hybrid Drivetrain” for Motorsport and Transportation applications
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.
Strategic outsourcing partner
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.
Related articles and news
We have a very busy exhibitions and conference calendar for 2024, meeting existing clients and introducing ourselves to new ones and learning more about the industries we serve. Click to find out where you can catch up with our team. Upcoming Exhibitions include: Battery Tech Show, The Battery Show, Electric & Hybrid Marine Expo, Cenex LCV, SMMT Electrified, Future Propulsion Show & Advanced Engineering Show.
PAST EVENT: The International Nuclear Manufacturing Summit 2022
Hosted by the Nuclear AMRC, the International Nuclear Manufacturing Summit 2022 will showcase opportunities in the major programmes and explore how suppliers can win work now and over the next 30 years. Our list of customers in this field include CERN, CEA, Elytt and Brookhaven internationally with UKAEA divisions Cullum, Harwell, Rutherford and Diamond Light in the U.K. We are also providing Switchgear suppliers such as Schneider Electric, GE Energy and Alstom with Busbars for products used with the sector.
PAST EVENT: Coiltech Italia 2022
Coiltech is the most qualified electromechanical Meeting-Point in its sector. The range of products offered by companies that exhibit at Coiltech covers all the production steps of electric motors, generators, electric pumps, transformers, and windings in general. Following a fantastic show in Germany (April 2022) – we will be back at Coiltech Italia, 28-29th September in Podenone, Italy. We will be showcasing our Core Packs and Busbars for electric motor applications.
Investing in Quality
To assist the constantly evolving challenges that face our highly experienced quality team at H V Wooding, we have recently invested in the super accurate Trimos height gauge and the Vision inspection system ‘InspecVision Planer’ for fast and accurate measurement of multiple parts.
High speed Bruderer press investment delivers major reshoring contract
Investment in a refurbished precision high-speed press is helping H V Wooding deliver a significant aerospace contract that has been re-shored from Spain. We have invested over £120,000 into new tooling and the installation of a Bruderer BSTA 25H to produce more than 28 million precision parts every year.
Electric Vehicle boost for HVW
Having been given a glimpse of a potential future should we make the switch to Electric Vehicles - with less air pollution and improved air quality being documented during the COVID-19 lockdown - more buyers are realising the benefits of moving away from petrol and diesel cars.