William Hughes is one of the UK’s 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.
Agile Manufacturing, Prototyping and Development Support
As experienced wire fabricators for automobile manufacture we support Tier 1s and OEM teams in component development, rapid prototyping, development support throughout the entire manufacturing phase and agile manufacturing to deliver repeatable quality at any production scale. This makes the facility especially valuable for customers operating in compressed automotive programme cycles, model-year refreshes or complex seating architecture projects.
From concept feasibility and early-stage modelling through to tooling, pilot runs and validation testing, our engineers work alongside customer R&D teams to co-develop and optimise components. In-house tooling and forming facilities allow us to iterate rapidly without relying on external subcontractors, enabling faster time to market and reduced development risk.
Overmoulded Wire Components for Automotive Interiors
Sector Experience and Product ExamplesWithin the William Hughes Group, we offer specialised plastic overmoulded bent wire components, primarily used in car seat systems and comfort modules. These hybrid components combine structural wire geometries with moulded plastic elements to deliver multi-functional parts that improve seat stiffness, integrate electronics, or eliminate the need for separate brackets and fasteners.
This overmoulding capability supports Tier 1 seating system suppliers and OEMs developing next-generation seat architectures, including luxury, ergonomic, and mass-market designs. Components are fatigue-tested and validated in-house under real-world seat lifecycle conditions.
Validated Durability in Busbar and Torsion Bar Manufacture
As OEMs transition to lightweight, high-conductivity materials such as copper alloys or aluminium for under-bonnet electrical distribution, the need for precision forming, secure insulation and mechanical resilience has grown sharply. We combine robotic forming and in-house fatigue testing to validate long-term performance, even under sustained thermal and mechanical load. This is especially important for applications where bar flex or vibration could compromise continuity or lead to early component fatigue.
Torsion bars, too, have become more complex. They’re no longer just structural supports, but tuned elements in seat safety systems, impact absorption zones, or closure mechanisms. William Hughes engineers these to tight tolerances using pre-hardened steels and progressive bending tools, with validation loops to simulate real-world operating cycles. These capabilities help de-risk late-stage design changes, shorten test cycles and ensure readiness for programme launch.
Eliminating Vibration-Induced Failure in EV Battery Assemblies
Our spring and wire form engineering for EV battery systems is developed in real-world operating conditions. We engineer locator clips and tension springs to resist vibrational loosening and fatigue over extended thermal cycles. Through prototyping and fatigue testing, we help customers select the optimal combination of material hardness, surface finish and coil geometry to maintain component stability without over-engineering.
Supporting High-Cycle Seat and Interior Mechanisms
Repeat load cycles in seats, consoles and actuators present a known fatigue risk, particularly where form complexity or non-standard kinematics are involved. William Hughes develops custom spring and wire sub-assemblies with optimised stress distribution and consistent forming tolerances across high volumes. Our advanced CNC coiling and forming technologies ensure the repeatability needed to meet lifetime performance criteria.
Ultrasonic Cleaning for Automobile Components to Micron-Level Standards
Our in-house ultrasonic cleaning, passivation and post-weld decontamination systems are tuned to remove particulates, flux residues and oils down to sub-micron levels. Where required, we integrate these processes with vacuum packaging or cleanroom-compatible bagging to prevent recontamination prior to final assembly. This end‑to‑end control not only preserves component integrity, but also significantly de‑risks the supply chain by ensuring that parts arrive at your facility ready for installation, eliminating uncertainty, rework, and delays further downstream.
Packaging, Kitting and Line-Side Integration
Our solutions are delivered in engineered kitting and packaging formats, reducing assembly time and eliminating the need for additional handling. Whether it’s a left/right spring pair for seat tracks or a clip with protective sleeving to prevent surface marring, our packaging is designed to your production flow, supporting traceability, efficiency and final fit confidence.
Design Validation Through Closed Loop Testing
Our facilities are equipped to fatigue-test springs and wire forms under simulated operational conditions. This allows us to verify not only the theoretical performance of a design, but also its manufacturability and reliability over time. For our customers, this creates a closed feedback loop between the design office and the production line, reducing risk and accelerating validation cycles.
Automotive Component Applications:
From seating to battery integration, our wire forms, springs and welded assemblies are engineered to meet the toughest performance requirements throughout a vehicle’s life. Applications include:
EV battery modules
Locator springs, interconnect wire forms, HV interlock brackets, terminal clips and busbar supports
Car seat structures and comfort systems
Frame-mounted wire forms, lumbar springs, cushion retention clips, under-seat bracket assemblies, plastic overmoulded car seat wire mats
Interior and trim systems
Formed clips, torsion springs used in glove boxes, armrests, air vents, and dashboard mechanisms
Sensor and actuator integration
Spring clips, shields and mounts for position sensors, drive-by-wire actuators and electronic throttle systems
Chassis and drivetrain support
Welded wire assemblies and high-strength springs used in clutch release systems, gear selectors and suspension linkages
Electrical connector housings
Custom retention springs, wire forms used in connector blocks and harnesses to prevent loosening, fretting, or loss of contact
Automotive Component Manufacture From Prototype to Line-Side
Step 1. Prototype
We collaborate with OEM and Tier 1 teams to translate conceptual designs or reverse engineer physical samples into production-ready prototypes. Material selection is guided by mechanical performance, corrosion resistance, formability and compatibility with post-processing steps such as coating or passivation. Tooling is developed in-house, allowing us to iterate quickly during prototyping and maintain control over critical dimensions during volume production. Thanks to this integrated approach, we are able to deliver prototypes of even highly complex wire forms and welded wire assemblies within 2–6 weeks, supporting rapid design validation and programme timelines. This process benefits from our expertise in custom wire fabrication for vehicle components, ensuring that both design intent and manufacturability are aligned.
Step 2. Finishes
Precision cleaning for automotive components is integrated into our workflow, ensuring that parts are delivered to customers in a state ready for assembly. Corrosion-resistant finishes are available to meet component-specific performance requirements, including pre-coated wire, Delta Tone, and KTL Black (E-Coating).
Step 3. Kitting or Packaging
We deliver complete kits and sub-assemblies to line-side, eliminating the need for additional handling. Kitting for automotive components is managed within our facilities, allowing procurement teams to source fully prepared sub-assemblies with confidence in both completeness and traceability. Packaging can be tailored to preserve cleanliness through to the point of use.
Proven Capability, Trusted Partnerships
William Hughes manufactures within an IATF 16949-certified quality framework across the UK, Poland and Bulgaria, ensuring that customers receive the same quality and process control regardless of manufacturing location. Our vertically integrated, multi-site strategy means customers benefit from consistent quality, agile development and scalable production. We are trusted because we provide confidence. Confidence that the component will fit, function, and endure as designed. Confidence that the supplier can adapt when specifications change. Confidence that the supply chain is secure, resilient, and transparent.
Talk to our automotive engineering team today to discuss your next programme.
