AUTOMOTIVE
William Hughes is one of the UK and Europe’s leading manufacturers for wire form fabrication and sub-assemblies for the Automotive sector, with facilities in the UK, Poland and Bulgaria.
In automotive manufacturing, every component, no matter how small, is a critical link between design intent and road-ready performance and has a direct impact on safety, comfort and helps to maintain long-term reliability of the vehicle across its full-service life.
The introduction of electric vehicles (EVs), lightweight materials and advanced driver assistance systems has increased the demand for dimensional accuracy, controlled material properties and contamination-free assembly. William Hughes supports Tier 1 and OEM automotive manufacturers with industry-specific expertise that combines wire form and spring design, CNC manufacture, ultrasonic cleaning and tailored kitting to ensure that components arrive at line-side ready for immediate installation.
Meeting the Challenges of the Automotive Supply Chain
We set ourselves apart as a leading manufacturer of wire form assemblies for automotive manufacture, with the knowledge and expertise of our engineering technicians. In the shift from Internal Combustion Engines (ICE) to Electric Vehicle (EV) manufacture, we help resolve design and manufacturing challenges that lead to component failure, high waste or excessive production costs. Our facilities offer advanced automation, precision testing and design validation tools to deliver production-ready solutions from first-off prototypes to full-scale line-side integration.
Other Products and Services from William Hughes Ltd
PASSIVATION
Passivation
At William Hughes, we specialise in precision passivation for stainless steel, using advanced chemical treatments and rigorous quality control to meet the highest industry standards, including AMS2700 and ASTM A967. Passivation is a chemical process used on corrosion resistant steels to remove free iron and surface contaminants without altering the material’s essential properties. This process restores the natural oxide layer, reducing the risk of corrosion and ensuring optimal functionality across a wide range of manufacturing applications.
Whether you require passivation for medical instruments, precision-engineered components or complex assemblies, William Hughes delivers results that meet stringent industry specifications.
Our Passivation Process
Our passivation process, which is Nadcap accredited and Honeywell Aerospace approved, involves a series of precise chemical treatments that eliminate contaminants from the stainless-steel surfaces. Our facility at Stalbridge incorporates 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 which involves moving chemical solutions from holding tanks into the main processing unit as required, helping to prevent damage as the parts do not move. The entire process is automatic and PLC controlled. Typical treatments are nitric acid and rinse cycles. These are followed by a final rinse in deionised water before a drying cycle.
We offer three service levels: standard five-day, express three-day and super-express 24 hours (subject to any testing requirements).
FINE WIRE
We offer a comprehensive range of fine wires. We have been stockists of Webster & Horsfall for over 50 years and can supply 1800 different wire types in various weights and finishes packaged to suit your particular requirements.
Our non-ferrous wire from Little Falls Alloys includes Beryllium Copper, Phosphor Bronze, Nickel Grade, Cupro Nickel, Copper, Nickel Silver, Brass, Zirconium Copper, Cadmium and Chromium-Copper in round, square, flat and shaped formats, coiled, on spools and in straight lengths.
For applications demanding high fatigue properties we also stock Suzuki-Garphyttan stainless steel wire.
PCB TEST POINTS
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.
William Hughes Ltd
Station Road, Stalbridge, Dorset, DT10 2RZ, United Kingdom
For over 200 years, William Hughes has been at the forefront of the UK wire industry. Today, this successful business is supported by four key activities - the manufacture of bespoke compression, tension and torsion springs, wire forms and assemblies, printed circuit test points and terminals, and specialist wire sales. The company offers design, engineering and prototyping services and is Nadcap accredited for heat treatment and room temperature tensile testing. It also has a 4000 square metre factory in Bulgaria to meet the demand for product across Europe.