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 in 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.
One of the facility’s core deliverables is the manufacture of seat mats and torsion bars, including composite wire and plastic structures designed to sit beneath the seat to support weight distribution and mechanical articulation. These components are fatigue-tested to withstand long-term use under dynamic conditions, helping ensure both occupant comfort and mechanical reliability.
The facility operates the following specialist processes:
CNC Wire Bending.
Our CNC bending stations can accommodate wire diameters from 2 mm to 12 mm and support multi-axis bending to produce tight-radius geometries with precise repeatability. These machines are PLC-controlled and ideal for the production of complex 3D wire forms used in seat structures, cable guides and EV-specific clips and retainers. In-line inspection and tool compensation ensure tolerances are maintained across extended batch runs.
Multi-Head Welding.
For assemblies requiring multiple simultaneous weld points, our multi-head welding systems offer high-speed throughput with high positional accuracy. These systems are supported by custom-built jigs designed in-house to ensure rapid fixture changes and consistent cycle times. This is especially beneficial for automotive seating frames and composite bracket assemblies.
Robotic MAG Welding Cells.
The site operates robotic MAG (metal active gas) welding cells using Fanuc and Yaskawa (Motoman) robots. These robotic systems deliver fully automated welding for repeatable, high-integrity joints on subframe assemblies, seat mats, and torsion bar components. These systems can be calibrated for EV chassis components and support structures. Real-time weld monitoring and offline programming allow us to switch between product variants with minimal downtime.
Manual Assembly Lines.
Alongside our automated systems, manual workstations support the sub-assembly of low- to mid-volume product families and those requiring functional testing or operator visual inspection. These lines are particularly well-suited to niche or pilot EV component production, where flexibility and human oversight are critical.
Capabilities
Together, these capabilities allow our Polish site to deliver highly repeatable manufacturing outcomes across a broad range of components and industries, while meeting the exacting standards of IATF 16949.
Capabilities include:
- CNC wire forming for diameters from 2 mm to 12 mm
- Fixed tooling set-ups for cost-efficient, high-volume production
- Multi-robotic MAG welding using Fanuc and Yaskawa robotic arms
- Manual welding bays for prototypes and low-volume variants
- Automated and manual assembly lines for multi-component sub-assemblies
- Supply chain integration for line-side-ready kitting
- Quality monitoring with in-line dimensional and visual inspection
Sector Experience and Product Examples
The Poland facility primarily supports the commercial vehicle and automotive interior markets. Components are designed for integration into seating systems, restraint assemblies and cabin infrastructure. Product families include:
- Seat mats
- Torsion bars for recliner and height adjust mechanisms
- Welded seat base structures
- Armature brackets and support frames
- Spring and wire clip components for automotive interiors
- Anti-vibration frames
- Welded composite structures using hybrid materials (steel/plastic)
The facility is experienced in managing long-run production schedules, high-volume manufacture with fixed tooling and automotive logistics systems.
Equipment and Infrastructure
The Polish factory benefits from a high-capacity shopfloor environment equipped for continuous multi-shift operation. Infrastructure includes:
- CNC bending and coiling machines with programmable logic controls
- Robotic MAG welding stations from Fanuc and Yaskawa (Motoman)
- Fixture design and in-house jig manufacture for accurate repeatability
- Integrated ERP and batch traceability from raw material to finished part
- Welding fume extraction and safety-certified production zones
In 2024, the site completed an infrastructure upgrade to improve workflow and throughput, including reconfiguration of cell layout and installation of new welding robots.
Leadership and Team
William Hughes Poland operates under the leadership of Tomasz Raczyński, Plant Manager, whose hands-on manufacturing expertise and strategic oversight ensure the site delivers consistently for high-volume OEM programmes. The strength of the Polish operation lies in the combined experience of its production, quality and logistics teams, many of whom have been retained from the site’s previous ownership and have decades of experience in wire and welded component manufacture.
Certifications and Quality Assurance
William Hughes Poland operates under the following accreditations:
- ISO 9001:2015 – Quality Management System
- IATF 16949 – Automotive Sector Certification
- ISO 14001:2015 – Environmental Management (recertified 2024)
All products undergo 100% inspection for key dimensional attributes and weld conformity, with real-time data capture available for client audit or internal SPC.
Why Choose William Hughes Poland?
Poland is a high-throughput location, ideal for long-run production of welded and formed assemblies. Its central position in Europe allows reduced lead times and stable logistics to key customer locations. The site works in coordination with William Hughes UK and Bulgaria to offer a blended production strategy, combining volume, prototyping and specialist processing depending on project needs.
- Proven capability in seat mats, torsion bars, and welded assemblies
- Robotic MAG welding with Fanuc and Yaskawa systems
- Fixed tooling setups for repeatable, cost-efficient wire forming
- Centrally located in Europe for efficient OEM logistics
- Integrated with William Hughes UK and Bulgaria for multi-site flexibility
