William Hughes started to supply the automotive industry nearly 30 years ago. Now it forms the largest part of our business, but our success has not been lightly won. It has been achieved by constant investment in new technology, the support of a highly skilled and dedicated workforce and by adhering to the highest quality standards.
Our global customer base includes Johnson Controls, Lear Corporation and CTS (global oem suppliers to the automotive industry). Also Proseat, Fehrer and such smaller companies as The Seat Design Co. and CAB Automotive which specialise in low volume production for the luxury car market.
In its core disciplines of bespoke spring and wire form design and manufacture, William Hughes can call upon a capability and expertise well beyond almost any other company operating within the same field.
With factories in Stalbridge, Dorset and Plovdiv, Bulgaria, each benefitting from a multi-million pound investment in plant and machinery together with the recent acquisition of Nosag Polska in Poland, William Hughes combines modern technology with traditional skills to bring products to market in the most refined, cost-effective and timely way possible.
These products comprise a broad range of compression, tension and torsion springs, wire forming including simple and complex 2D and 3D wire forms, printed circuit test points and terminals, and specialist wire sales.
Throughout the past two centuries, the success of William Hughes has been based on the traditional virtues of a family firm - commitment to its customers, concern for quality and service - allied to continual improvements in production and technology to meet the precise specification of each individual requirement in the most appropriate way.
The resources provided by William Hughes are amongst the most extensive and sophisticated in Europe, with the capability of fulfilling orders, however large or small, with equal facility, and an established administration and distribution function that ensures continuity of supply, rapid delivery and competitive prices on every single item.
The variety of springs and wire forms available is almost infinite in a choice of metals which is nearly as wide including stainless steel, brass phosphor bronze, beryllium copper and nickel-chrome alloys.
PROTOTYPING
William Hughes has many years of design and manufacturing experience and can offer its customers a rapid design and prototyping service in a range of materials. This service is particularly suited to the aerospace and automotive industries where small quantities are required for test and evaluation with the capability to move to volume production once a final design is agreed.
SUB-ASSEMBLIES
Through the 90’s the company expanded to includes the manufacture of sub-assemblies. These sub-assemblies are still based on wire but techniques have been developed such as welding, punching, pointing, chamfering, nibbing, threading, clipping and many more that add value to the product for our customer. Through the next decade we expanded our range of in-house surface treatments to include shot peening, ultra-sonic cleaning, KTL black coating, painting, Delta-Tone™ and nylon coating.
OUR EUROPEAN OPERATION
In 2004, sensing the need to address the challenge of an expanded Europe, William Hughes set up a purpose-built factory near Plovdiv in Bulgaria, the better to compete in an increasingly cost-conscious market and also to facilitate speedy delivery into its many customers in mainland Europe. Today our Plovdiv factory has twice doubled in size and is currently around 6,500 square metres.
Our work force has more than trebled to 200 skilled employees even allowing for the fact that we have added automation-handling robots for secondary processes and collaborative robots for packing and repetitive tasks.
The Plovdiv factory now houses over 50 CNC wire bending machines along with 9 injection moulding machines, both vertical and horizontal, for over-moulding projects utilising rotary and fixed platens.
UK EXPANSION
Further expansion took place in 2008 with the acquisition of the springs and wire form business of Baumann Springs and Pressings (UK) Ltd.
NOSAG POLSKA
Nosag Polska, previously part of the DEFTA Group, was acquired by William Hughes in the autumn of 2017.
Based in Tychy in southern Poland, Nosag Polska is a major manufacturer of seat mats, wire frames and bent wire parts, predominantly for the automotive industry. This makes the Company a perfect fit for William Hughes with our complementary manufacturing facilities in Dorset and Bulgaria but providing us with a manufacturing hub with easy access to mainland Europe and the Baltic States.
Nosag is a leading supplier to all the major car interior and car seat manufacturers in Europe. The Company enjoys a reputation for service and quality similar to our own which has led to a smooth transition of ownership and opportunities for both operations to benefit from the experience and expertise of the other.
PRECISION SPRINGS FOR THE AEROSPACE INDUSTRY
William Hughes specialises in the manufacture of precision, high specification springs and its modern manufacturing facilities, together with state of the art spring measurement systems, are ideally matched to the exacting requirements of the aerospace industry.
Springs manufactured by William Hughes are used in vital items of aerospace equipment including oxygen systems, access hatches and the solenoid valves used to control the hydraulic and cabin pressure systems.
William Hughes is an approved supplier to many leading companies in the aerospace industry and is an audited and approved supplier to Honeywell. Other customers include BAE, Eaton Aerospace, Lockheed Martin, Meggit and M.E.L. Aviation.
To meet the specifications for high temperature performance, many springs for the aerospace industry are manufactured in exotic materials such as Nimonic, Inconel and Ni-span. These expensive materials are more difficult to work than conventional materials and William Hughes has the machinery and expertise to use these materials with high accuracy and minimum wastage.
For critical applications it is essential that any lubricants and debris from the manufacturing process are removed from the spring before it is despatched to the customer and William Hughes offers an ultrasonic cleaning process to meet aerospace standards for cleanliness.
William Hughes Ltd is Nadcap accredited for heat treatment, room temperature tensile testing (materials testing laboratory) and chemical processing.
QUALITY ASSURANCE
Our aim at William Hughes is to meet and exceed the expectations of our customers in every way adhering to principles of continuous improvement and zero defect. Quality systems to ISO 9001:2000, ISO/TS 16949:2002 the latest automotive standard and AS9100 for aerospace ensure consistency and accuracy of supply.
A SECURE FUTURE
Each year the company invests in new plant and equipment to the tune of 10-15% of turnover with the medium and long term strategy of positioning itself as a volume supplier of quality products to demanding customers for generations to come.
14/10/2024 -
Spring Capabilities What goes into making a successful spring? A lot more than you think! And getting the perfect balance across all the many inputs is what sets William Hughes apart from its competitors.
30/08/2023 -
Significant investment keeps automotive supply chain agile and just-in-time William Hughes, a specialist manufacturer of springs and wire components, has adapted quickly to a serious increase in demand from a tier-one automotive seating customer, thanks to a major new investment in robotic welding cells and associated tooling and fixtures.
27/04/2023 -
Over-moulded Lumbar Structure William Hughes has been helping a prominent European car manufacturer develop an over-moulded carrier plate and wire frame for use as the backrest on the driver and passenger seats in its range of saloon cars and SUVs.
10/01/2023 -
Technology investment boosts cleanroom capabilities at William Hughes William Hughes, a specialist manufacturer of springs and wire components, has enhanced the capabilities of its 80 m2 Class 7 cleanroom with its investment in a digitally controlled Ultrawave Neon 60 Ultrasonic Cleaning System.
09/06/2022 -
William Hughes is welded to success William Hughes has become an authority in the supply of welded wire assemblies, primarily for the automotive industry. The Company’s expertise in MIG, MAG, TIG, spot/resistance and Butt welding processes has led to it establishing a total of 33 welding cells across its three factories in the UK, Poland and Bulgaria.
13/01/2022 -
New tech, new capacity & new capabilities at William Hughes Advanced assembly, forming and fabrication assets from Sertec’s recently closed springs and wire forms division have been given a new lease of life at Dorset-based William Hughes Ltd.
09/08/2021 -
Insulated bus bars formed without coating damage thanks to new approach to bending William Hughes Group announces that it has perfected a method of composing and forming complex automotive electric vehicle (EV) bus bar geometries out of pre-coated copper stock; and can do so in such a way that the insulation/protective cover remains completely viable along the length of the bar.
12/08/2020 -
Springing into action saves the day for automotive tier one William Hughes has come to the aid of a leading automotive tier-one seat manufacturer; a rescue mission that was only made possible by the company’s broad set of skills and advanced capabilities in the world of complex wire forms.
08/07/2019 -
William Hughes introduces metrology services for high precision manufacturing following the acquisition of JK Metrology World-leading spring, wire form and assembly specialist William Hughes, has expanded its range of specialist services for the manufacturing industry with the acquisition of JK Metrology & Quality Services of Liskeard, Cornwall. JK Metrology is a well established metrology and quality consultancy for ISO 17027, ISO 9000 etc. and offers a UKAS calibration service to ISO 17025.
27/09/2018 -
Passivation explained and demonstrated The latest video from William Hughes Ltd features the passivation process facility based at the Company’s headquarters in Stalbridge, Dorset.
14/09/2017 -
William Hughes meets new challenges for high performance spring in critical aerospace application William Hughes has been manufacturing precision, high specification springs for many years, and is well equipped to meet the exacting demands of the aerospace industry including its special requirements for materials, specifications, manufacturing tolerances, cleanliness and packaging.
07/08/2017 -
William Hughes takes the stress out of spring specification Springs are used in many everyday items such as cars, electrical appliances and business hardware. But although springs may seem commonplace, each one needs to be designed to meet a specific need of in terms of size, performance and durability. With so many options of spring types, materials and dimensions, many users need a helping hand to develop a spring that meets the precise needs of each application.
22/03/2017 -
Critical components cleaned to the most demanding quality standards, approvals and specifications William Hughes, the specialist manufacturer of springs and bent wire components for the global automotive and aerospace industries, now offers an expanded range of ultrasonic and non-ultrasonic cleaning techniques for critical components to the highest international and governmental approval standards
13/12/2016 -
William Hughes shares spring making secrets on youtube Ever wondered how springs are made? William Hughes Ltd, one of the UK’s foremost spring makers, has produced a video demonstrating the manufacturing processes involved in producing the hundreds of thousands of bespoke springs delivered to customers each week.
18/02/2016 -
Clean bill of health for William Hughes Since William Hughes, a specialist manufacturer of springs and wire components, acquired AC Services in the summer of 2015, the company has been busy establishing an 80m² high specification clean room at its Stalbridge, Dorset headquarters.
18/01/2016 -
Specialist springs from William Hughes help improve car comfort and safety When you are adjusting the height and reach of the seat in your car, you probably don’t give a thought to the mechanism that allows this to happen. Springs form an important part of these mechanisms and they are used to ensure smooth and reliable operation. Each application is different and requires a spring that has been individually designed to meet the requirements for force, physical size and operational life.
11/04/2014 -
William Hughes celebrates 10 years of success in Bulgaria William Hughes will be celebrating the 10th anniversary of the opening of its factory in Bulgaria with an event being held at its manufacturing facility near Plovdiv.
16/09/2013 -
Coiled and ready for action Leading international wire industry specialist William Hughes Ltd is enjoying increasing success in a market that has the potential to offer enormous growth opportunities.
08/08/2013 -
Wire-form & Spring specialist expands services portfolio William Hughes Ltd, a leading manufacturer of springs, bent wire-forms and assemblies, is responding to growing industry demand for single source solutions by introducing a number of new ‘added-value’ services for its customers. Among the new controlled processes are steel and glass shot peening, ultrasonic cleaning and tensile testing to very high national standards such as AMS (Aerospace Material Specifications) or precise customer specifications.
28/06/2013 -
William Hughes continues to grow its manufacturing facilities in Bulgaria When William Hughes opened its new production facility in Bulgaria in 2004, it was hard to imagine that nine years later the operation would have proved so successful that the factory has expanded four-fold.
30/01/2013 -
Plasma Welding expertise at William Hughes William Hughes Ltd is demonstrating its credentials as a leading international wire industry specialist by exploiting innovative plasma welding processes to manufacture a variety of interesting wire products destined for industries ranging from consumer electrical goods through to automotive.
18/01/2013 -
Bent Wire from William Hughes gets you on the move The accelerator pedal assembly on many modern cars looks to most people like a piece of cleverly bent wire - but to manufacturer William Hughes Ltd, it is a critical component with precise dimensions that has been designed to meet key safety requirements.
20/12/2012 -
William Hughes Spring Technology at the heart of Deltex Blood Flow Monitor Following a recent recommendation from NICE (the National Institute for Clinical Health and Excellence) and predicted savings of £1,100 for every hospital patient undergoing surgery, the CardioQ-ODM™ (oesophageal Doppler monitor) from Deltex Medical looks set to transform patient care. Featuring innovative spring technology from William Hughes Ltd that is pivotal to its successful application, NHS authorities and trusts can no longer afford to ignore this impressive medical device.
07/12/2012 -
Speedy wire solution to rear car seat frame challenge When an international tier one supplier of automotive interior products wanted rapid supply of 150 prototype rear seat wire-frames for a UK-built, leading-brand hatchback, only one company was able to answer the call – William Hughes Ltd.
05/09/2012 -
Need double torsion springs? No problem for William Hughes While some spring manufacturers struggle with the complex shape of double torsion springs, William Hughes has invested in the latest CNC technology machines to fully automate the production process.
03/09/2012 -
William Hughes achieves NADCAP accreditation Springs and wire formed assemblies specialists, William Hughes, has achieved NADCAP accreditation for heat treatment and room temperature tensile testing.
16/07/2012 -
Hughes expands Compression and Torsion Spring ranges One of the leading manufacturers and suppliers of springs, wire-forms and assemblies, William Hughes, has expanded its manufacturing capabilities, announcing that it can now form compression springs in wire sizes up to 8mm diameter and torsion springs in wire up to 6mm diameter.
approvedbusiness.co.ukWilliam Hughes Ltd Tel: 01963 363377
