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William Hughes Ltd

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Station Road,
Stalbridge,
Dorset,
DT10 2RZ,
United Kingdom

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Products / Services

Design

Every spring or wire part produced by William Hughes is custom-made to suit a particular application. Customers involve us at an early stage in each and every wire-based project so that problems of space, performance, material and cost can be addressed at the outset of the design process.

Our design and application engineers enjoy state-of-the-art facilities for the in-house design of products and machine tools.

Springs

Bespoke Spring Manufacturer

Precision-engineered springs remain at the centre of mechanical systems, delivering force, motion control and resilience across multiple sectors such as aerospace, automotive, medical, and nuclear. William Hughes offers full-service support from concept to production, underpinned by advanced CNC coiling technologies, statistical quality control and an integrated automation approach. Recognised as a leading Tier 1 manufacturer by assembly-level OEMs for springs and spring assemblies, we specialise in close-tolerance spring design optimised for performance-critical environments. Our engineers ensure every component meets your specification for load, free length, fatigue resistance and material compliance.

Bespoke Springs for Complex Applications

As one of the UK's longest-established spring manufacturers, our engineering team brings over 100 years of sector-specific expertise, supporting product design from early-stage feasibility to validation and final release. With advanced simulation tools, Institute of Spring Technology design software, in house fatigue testing facilities and CNC coiling capabilities, we reduce time-to-prototype while maintaining full control over the physical dimensions and the load profiles.

Every spring is defined not only by geometry, but by its behaviour in application. That’s why we collaborate closely with R&D and procurement leads across the automotive, medical and aerospace sectors to design prototypes with mechanical integrity, consistent repeatability and the best possible cost-to-performance ratio.

Using our CNC coilers and closed-loop vision systems, we can produce springs with sub-millimetre accuracy, sorting components in real-time with SPC (Statistical Process Control) technology. Whether you’re designing for fatigue, rebound, corrosion resistance or magnetism, we’ll ensure your specification is both feasible and manufacturable at scale.

Wire Forms & Assemblies

Wire forming, bending and assembly is a major part of our business. If something can be made out of wire, we’re the people to make it.

If you have a 2D or 3D wire form that involves twists, turns, spirals, protrusions, indentations or just plain bends, we have both the expertise and the state-of-the-art automation to provide exactly what you need.

We also have the facility to design and manufacture tools, jigs, and gauges in-house, which means that not only can we test designs for feasibility before manufacture, but it also greatly reduces the lead time compared to outsourcing.

Aerospace

In 2009, the UK aerospace industry generated revenue in excess of £22 billion. This amounts to the largest aerospace income in Europe, and is second only to America globally. Around 9000 companies are involved in aerospace work around the UK, but it is the south of England that has become the established home of the UK aerospace industry with companies like Honeywell, BAe Systems, Eaton Aerospace, Lockheed Martin, Meggitt and M.E.L Aviation.

PCB Test Points

PCB Test Points & Terminals

Prototype work and volume production

Our PCB test points and terminals feature a large loop for easy probe attachment or to facilitate the clipping on of other components. They are ideal for components which need frequent replacement and are also suitable for raising hot components above the surface of the PCB.

A glass bead in a choice of eight colours for identification purposes ensures a snug fit on the board. White, yellow, black, brown, blue, pink, red and green are available ex-stock with other colours to meet special requirements. The unique shape of the test point will not damage through-plated holes during assembly yet prevents any movement prior to soldering.

Passivation

William Hughes offers a state-of-the-art automated passivation plant with novel functionality in that there is no manual ‘dunking’ of component baskets from station-to-station, as with traditional systems. Instead, the plant performs a ‘fluid transfer’, moving chemical solutions from holding tanks into the main processing unit as required, thus helping to prevent damage as parts do not move. The entire process is automatic and PLC controlled.

ISO Class 7 Cleanroom

William Hughes’ new 80m² cleanroom is constructed to Class 7 standards in accordance with ISO 14644-1 which is the equivalent to a Class 10,000 cleanroom using the Fed Stan 209E.

The cleanroom ensures that hydraulic, LOX (liquid oxygen), oxygen and other critical components can be cleaned to the most demanding quality standards, approvals and specifications. It incorporates an inspection dark room so that parts can be viewed under ultra-violet light.

Automotive

William Hughes started to supply the automotive industry nearly 30 years ago. Now it forms the largest part of our business, but our success has not been lightly won. It has been achieved by constant investment in new technology, the support of a highly skilled and dedicated workforce and by adhering to the highest quality standards.

Our global customer base includes Johnson Controls, Lear Corporation and CTS (global oem suppliers to the automotive industry). Also Proseat, Fehrer and such smaller companies as The Seat Design Co. and CAB Automotive which specialise in low volume production for the luxury car market.

Fine Wire

Stockists of Fine Wire

Piano Strings

We supply sets and single strings for manufacturers, tuners, and reconditioners for all types of piano including upright, grand, concert grand and square grand. Plated or polished steel music wire, single or double covered, German, Continental or English loops.

Nosag Polska

One of Europe’s Leaders in Automotive Component Manufacturing

William Hughes Poland specialises in high-volume, welded and formed metal components, and is strategically located to serve major automotive OEMs and Tier 1 suppliers across Central and Eastern Europe. The facility has grown from the foundations of Nosag Polska, a specialist in welded seat structures and complex wire assemblies, acquired by William Hughes in 2017. With decades of specialist knowledge, the Polish site supports William Hughes’ wider manufacturing operations, supporting large-scale production with full quality traceability, consistent throughput, and automotive sector compliance.

High-Volume Welding, Assembly and Wire Forming

Our Polish site specialises in the high-volume manufacture of welded wire assemblies, including automotive seating structures, seat mats and torsion bars for applications, including electric vehicle (EV) and ICE assembly. As OEMs transition towards lightweight and modular EV design, our capabilities allow for the efficient manufacture of wire-based structural supports, battery compartment reinforcements and vibration-dampening spring assemblies.

Cataphoretic Paint Line (KTL)

A new cataphoretic paint line has been installed at our factory in Plovdiv, Bulgaria and is proving ideal for interior automotive products. Offering high corrosion resistance and anti-squeak properties, this facility is well-suited to automotive seating as well as a variety of other applications.

William Hughes Bulgaria

Since we opened our Plovdiv factory in 2004, our production capacity in Bulgaria has grown by leaps and bounds, largely due to our ideal geographical position and the ease with which we can deliver into central Europe.

Our original 2000 square metres now stands at 6,500. Our work force has more than trebled to 200 skilled employees, even allowing for the fact that we have added automation-handling robots for secondary processes and collaborative robots for packing and repetitive tasks.

The Plovdiv factory now houses over 50 CNC wire bending machines along with 9 injection moulding machines for over-moulding projects.

About us

In its core disciplines of bespoke spring and wire form design and manufacture, William Hughes can call upon a capability and expertise well beyond almost any other company operating within the same field.

With factories in Stalbridge, Dorset and Plovdiv, Bulgaria, each benefitting from a multi-million pound investment in plant and machinery together with the recent acquisition of Nosag Polska in Poland, William Hughes combines modern technology with traditional skills to bring products to market in the most refined, cost-effective and timely way possible.

These products comprise a broad range of compression, tension and torsion springs, wire forming including simple and complex 2D and 3D wire forms, printed circuit test points and terminals, and specialist wire sales.

Throughout the past two centuries, the success of William Hughes has been based on the traditional virtues of a family firm - commitment to its customers, concern for quality and service - allied to continual improvements in production and technology to meet the precise specification of each individual requirement in the most appropriate way.

The resources provided by William Hughes are amongst the most extensive and sophisticated in Europe, with the capability of fulfilling orders, however large or small, with equal facility, and an established administration and distribution function that ensures continuity of supply, rapid delivery and competitive prices on every single item.

The variety of springs and wire forms available is almost infinite in a choice of metals which is nearly as wide including stainless steel, brass phosphor bronze, beryllium copper and nickel-chrome alloys.

PROTOTYPING
William Hughes has many years of design and manufacturing experience and can offer its customers a rapid design and prototyping service in a range of materials. This service is particularly suited to the aerospace and automotive industries where small quantities are required for test and evaluation with the capability to move to volume production once a final design is agreed.

SUB-ASSEMBLIES
Through the 90’s the company expanded to includes the manufacture of sub-assemblies. These sub-assemblies are still based on wire but techniques have been developed such as welding, punching, pointing, chamfering, nibbing, threading, clipping and many more that add value to the product for our customer. Through the next decade we expanded our range of in-house surface treatments to include shot peening, ultra-sonic cleaning, KTL black coating, painting, Delta-Tone™ and nylon coating.

OUR EUROPEAN OPERATION
In 2004, sensing the need to address the challenge of an expanded Europe, William Hughes set up a purpose-built factory near Plovdiv in Bulgaria, the better to compete in an increasingly cost-conscious market and also to facilitate speedy delivery into its many customers in mainland Europe. Today our Plovdiv factory has twice doubled in size and is currently around 6,500 square metres.

Our work force has more than trebled to 200 skilled employees even allowing for the fact that we have added automation-handling robots for secondary processes and collaborative robots for packing and repetitive tasks.

The Plovdiv factory now houses over 50 CNC wire bending machines along with 9 injection moulding machines, both vertical and horizontal, for over-moulding projects utilising rotary and fixed platens.

UK EXPANSION
Further expansion took place in 2008 with the acquisition of the springs and wire form business of Baumann Springs and Pressings (UK) Ltd.

NOSAG POLSKA
Nosag Polska, previously part of the DEFTA Group, was acquired by William Hughes in the autumn of 2017.

Based in Tychy in southern Poland, Nosag Polska is a major manufacturer of seat mats, wire frames and bent wire parts, predominantly for the automotive industry. This makes the Company a perfect fit for William Hughes with our complementary manufacturing facilities in Dorset and Bulgaria but providing us with a manufacturing hub with easy access to mainland Europe and the Baltic States.

Nosag is a leading supplier to all the major car interior and car seat manufacturers in Europe. The Company enjoys a reputation for service and quality similar to our own which has led to a smooth transition of ownership and opportunities for both operations to benefit from the experience and expertise of the other.

PRECISION SPRINGS FOR THE AEROSPACE INDUSTRY
William Hughes specialises in the manufacture of precision, high specification springs and its modern manufacturing facilities, together with state of the art spring measurement systems, are ideally matched to the exacting requirements of the aerospace industry.

Springs manufactured by William Hughes are used in vital items of aerospace equipment including oxygen systems, access hatches and the solenoid valves used to control the hydraulic and cabin pressure systems.

William Hughes is an approved supplier to many leading companies in the aerospace industry and is an audited and approved supplier to Honeywell. Other customers include BAE, Eaton Aerospace, Lockheed Martin, Meggit and M.E.L. Aviation.

To meet the specifications for high temperature performance, many springs for the aerospace industry are manufactured in exotic materials such as Nimonic, Inconel and Ni-span. These expensive materials are more difficult to work than conventional materials and William Hughes has the machinery and expertise to use these materials with high accuracy and minimum wastage.

For critical applications it is essential that any lubricants and debris from the manufacturing process are removed from the spring before it is despatched to the customer and William Hughes offers an ultrasonic cleaning process to meet aerospace standards for cleanliness.

William Hughes Ltd is Nadcap accredited for heat treatment, room temperature tensile testing (materials testing laboratory) and chemical processing.

QUALITY ASSURANCE
Our aim at William Hughes is to meet and exceed the expectations of our customers in every way adhering to principles of continuous improvement and zero defect. Quality systems to ISO 9001:2000, ISO/TS 16949:2002 the latest automotive standard and AS9100 for aerospace ensure consistency and accuracy of supply.

A SECURE FUTURE
Each year the company invests in new plant and equipment to the tune of 10-15% of turnover with the medium and long term strategy of positioning itself as a volume supplier of quality products to demanding customers for generations to come.