Trusted Sub-assembly Partner for ICE and EV Supply Chains
As a trusted partner to Tier 1 automotive suppliers, William Hughes brings decades of experience in producing wire form and spring components for car seat systems. Our capabilities cover the design, prototyping and manufacture of engineered wire forms, springs, and welded sub-assemblies, all delivered meeting quality standards and full process traceability.
In both ICE and EV supply chains, comfort, structural integrity and safety are controlled to ±0.1mm tolerances. Our contribution to seat system performance is built on material science, automated manufacturing technologies and collaboration with OEM and Tier 1 design teams. As the shift towards electric vehicle manufacture accelerates, we help seating system developers respond rapidly to new criteria, weight reduction and modularity demands, without compromising strength, compliance or cost-efficiency.
End-to-End Expertise in Automotive Seat Component Supply
William Hughes provides full life cycle support for seat component manufacture, from wire form design and prototyping, through CNC bending, welding, forming and assembly, to in-line testing and delivery. Our production lines are developed to meet the fast-paced, high-volume demands of global automotive programmes.
Our expertise includes:
- Seat wire frames and reinforcement structures
- Tension springs and wire clips for lumbar and recliner mechanisms
- Composite mat structures combining plastic and steel
- Electrical contact springs for smart seat modules
- Seat locator wires and fixing clips for accurate, repeatable assembly
- Resistance welding of hybrid assemblies (steel/plastic/composite)
We operate advanced robotic welding cells, fully automated spring coiling machinery and in-line vision inspection systems — ensuring consistent dimensional accuracy, mechanical strength and part integrity.
Car Seat Systems Adapting for EV
While our track record in internal combustion engine platforms is extensive, William Hughes is also actively engaged in developing next-generation solutions for electric vehicle (EV) seating systems.
EVs present new engineering priorities, such as reduced NVH (noise, vibration, and harshness), lower overall weight and more flexible interior architecture. These shifts have a direct impact on seat structure design, particularly the selection of component materials, the integration of electronics and the kitting of sub-assemblies.
Our engineers work closely with OEMs and seating Tier 1s to meet these challenges through:
- Lightweight wire form optimisation, reducing material use while preserving mechanical performance
- Multi-material integration, e.g. plastic-steel hybrid mats and vibration-damping wire spring systems
- Design for assembly (DFA) — streamlining EV seat structure complexity for faster, error-free production
- Precision prototyping, enabling fast iteration during platform development or line transition phases
The ability to re-engineer seat components for EV-specific applications, without disrupting production readiness, demonstrates William Hughes’ agility and value as a long-term strategic partner.
Fatigue-Tested Torsion Bars and Seat Mats for Recliner and Height Adjustment Systems
To further support comfort and compliance in seat design, William Hughes manufactures precision torsion bars and seat mat assemblies for recliner and height adjustment mechanisms. These components are critical in controlling movement dynamics and long-term comfort within the seat structure.
Our dedicated fatigue testing facilities allow us to validate torsion bars and seat mats under real-world load conditions and extended duty cycles. By simulating the repetitive stress experienced in automotive environments, we ensure that every part meets the highest standards of mechanical integrity, deflection control and lifespan performance.
Whether integrated into legacy ICE seat frames or adapted for the latest EV platforms, these elements are engineered and tested to balance user ergonomics, mechanical resilience and cost-effective manufacturability.
Our Investment in Welding, Automation and Scalability Innovation
Our recent £1.4 million investment in robotic welding technology has unlocked new capacity and flexibility for sub-assembled seat frame production. Multiple articulated-arm welding cobots operate within our UK and European facilities, configured for high-speed, low-defect manufacture of repeatable assemblies.
Key benefits include:
- Precise, consistent welds across multi-point joints
- Reduced takt time on high-volume production lines
- Adaptive programming to support new seat frame geometries
- Support for low-volume prototyping alongside serial production
This capability was developed to reinforce our role as a leader in car seat frame manufacture capable of meeting both legacy ICE and EV demands.
Supporting Seat Comfort, Compliance and Cost-Efficiency
Springs and wire forms are often unseen but are essential to user experience, safety, and product compliance. Our spring manufacturing for car seat frames includes both standard and custom geometries, with tight tolerances on force, deflection and fatigue life.
Common applications include:
- Lumbar support tension springs
- Seatbelt wire clips and guides
- Return springs for adjuster mechanisms
- Load-compensating spring elements in comfort zones
With full in-house design and test facilities, we optimise spring design parameters to match application-specific load cycles and environmental demands. This ensures every spring is fit for long-term, high-reliability use, supporting Tier 1 customers in their global quality assurance and homologation programmes.
Integration with Tier 1 Development Teams
From early-stage seat concept development through to JIT production scheduling, William Hughes offers integration with customer workflows. Our engineers support 3D CAD modelling, prototype iterations and material selection reviews enabling co-development of sub-assemblies that are robust, cost-effective and production-ready.
We have supported leading European seat manufacturers in:
- Designing noise-reducing locator clips for EV-specific quiet cabins
- Co-developing hybrid mat assemblies combining thermoplastics with precision-formed steel wire
- Rapid prototyping of tension spring systems to rescue time-critical vehicle programmes
These collaborations highlight our commitment to building long-term partnerships and optimising automotive supply chains with engineering insight, fast lead times, and automated process control. By offering fully traceable, in-house manufacturing across our UK and European sites, we help Tier 1s reduce dependency on global logistics, mitigate supply chain risk and shorten time-to-market. Our vertically integrated model supports localised, just-in-time (JIT) delivery, enabling leaner inventory management. In optimising automotive supply chains, William Hughes actively contributes to sustainable manufacturing goals by investing in energy-efficient automation, minimising material waste through precision engineering and deploying solar energy infrastructure across our UK and European sites, helping our customers meet Scope 3 carbon reduction targets without compromising on quality or performance.
Why Choose William Hughes
Over 200 years of engineering heritage
Trusted supplier to aerospace, automotive and medical sectors
In-house tooling, test and quality assurance functions
Automated and robotic manufacturing capabilities
Certified to ISO 9001, IATF 16949, ISO 14001 and AS9100
Active sustainability programme aligned with Net Zero 2050
Let’s Discuss Your Seat System Requirements
Whether you’re looking to optimise an existing seating programme or develop new sub-assemblies for future EVs, William Hughes has the manufacturing capability, engineering design and quality assurance processes to support your goals.
Contact us to explore how we can support your next automotive seating project.