Powder Coated Busbars
H V Wooding manufactures powder coated busbars for electric vehicles, hybrid systems and advanced energy applications. From prototypes to mid-volume production, we combine precision manufacturing with robust insulation to deliver reliability where it matters most.
As EV voltages increase, insulation becomes critical. Powder coating provides a tough dielectric layer that protects against electrical stress and mechanical handling, offering a far more durable and safety-critical solution than paint. To guarantee integrity, every busbar undergoes holiday testing — a non-destructive inspection that detects even the smallest pinholes before parts leave our factory.
Our Capabilities
Precision engineering is essential to ensure busbars fit complex EV battery packs and power systems. At H V Wooding, bends and radii are formed with accuracy to prevent clearance issues, edges and surfaces are finished to support coating adhesion, and flatness is carefully controlled for consistent assembly. Each batch is produced to the same dimensional standards, reducing vibration wear and ensuring repeatable quality.
Our advanced processes — including laser cutting, CNC machining, forming and electroplating — enable us to produce complex busbars quickly and accurately, supporting customers from prototype through to mid-volume production. Quality assurance is built into every stage, with dimensional checks, coating inspections and surface testing ensuring long-term performance and reliability.
We also collaborate closely with design engineers to optimise busbar geometry for manufacturability without compromising performance. Early adjustments to bend radii or clearance for coatings can reduce cost and lead time while improving service life.
With over 50 years of precision manufacturing expertise, H V Wooding has a proven track record in EV, marine and high-performance sectors. Our UK facilities supply customers worldwide with holiday-tested busbars that deliver safety and durability in the most demanding applications.
Contact Us
Looking for a reliable partner to manufacture powder coated busbars for your EV or energy project?
📞 Call us on +44 (0)1303 264471
📧 Email sales@hvwooding.co.uk