Molded wire harness tool assembly

An overmold system for producing an over molded wire harness comprising:

• a positive mold including a plurality of interchangeable modular positive molds;
• a negative mold tool die produced from the positive mold and adapted to receive a wire harness and an overmold material that forms the overmold for the wire harness;
• at least one shut-off insert placed in the negative mold tool die to prevent the overmold material from overflowing from the negative mold tool die;
• an assembly board that receives the negative mold tool die;
• and
• at least one formable insert comprising:
• a pliable material that holds a shape once formed and substantially maintains that shape during application of the overmold material, disposed around at least a portion of a wire bundle of the wire harness to form a three dimensional shape for the wire harness that conforms to a shape of a vehicle component prior to application of the overmold material, and
• at least one notch to identify a bending point of the wire bundle,
• wherein the plurality of interchangeable modular positive molds includes at least one section that allows a portion of the wire harness to extend out over the overmold facilitating a connection to a component.