WILLIAM HUGHES BULGARIA
William Hughes Bulgaria supports a purpose-built 7000 square metre factory near Plovdiv which opened for business in 2004 as a centre for high volume production in a mainland Europe location.
In the beginning, the Bulgarian factory was simply involved with wire bending but as demand for its services has grown, so new machinery and processes have been installed. Massive changes inside the factory now include 35 CNC wire bending machines, seven vertical and two horizontal injection moulding machines and two nylon plastic coating lines along with MAG, MIG and spot welding. There are seven robotic welding cells complemented by an Electrophoretic black paint line and Deltatone Finishing.
Other Products and Services from William Hughes Ltd
ELECTROPHORETIC PAINTLINE (KTL)
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.
AUTOMATION & ENGINEERING DEVELOPMENT
We invest significantly in simulation, prototyping and production validation, including finite element analysis (FEA), tolerance stack-up assessment and rapid prototyping using soft tooling or modified jigs. The Stalbridge site features robotic welding machines including 6-axis welding cobots for the repeatable and highly consistent production of complex welded assemblies. These systems are ideal for precision welds, bracket assemblies and other load-bearing components where micro-level consistency in joint strength is essential. Our on-site engineer teams are always available to support customers with:
• Yield improvement and tolerance reduction initiatives
• Prototype-to-production transitions with low-risk scaling
• Design for Manufacture (DfM) and reverse engineering services
This investment in automated welding solutions allows us to guarantee both quality and efficiency, particularly for customers under pressure to meet stringent automotive tolerances and validation criteria.
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.