Process of fabricating wiring harness

A method of forming flexible wiring harnesses comprising

• placing an adhesive coated first flexible plastic sheet, adhesive side up, in contact with a positioning jig and a platen,
• applying a vacuum through hold-down tubes to temporarily maintain said flexible plastic sheet in contact with the positioning jig and platen,
• unreeling a conductive wire from a spool under control of an actuator,
• feeding said wire under control of a controller to a cut-off actuator,
• cutting said wire after a prescribed length of wire has passed said cut-off actuator,
• feeding said wire under control of the controller between a flattening actuator and an anvil,
• flattening said wire on said anvil at prescribed places,
• feeding said wire under a press-down wheel onto the adhesive coated plastic sheet,
• positioning the press-down wheel, under control of the controller, to guide said wire and to press it down continuously in a chosen pattern onto the adhesive coated plastic sheet,
• moving the platen relative to X and Y axes in accordance with a pre-determined program to locate the conductive wire on the first plastic sheet in accordance with the desired pattern,
• placing a second flexible plastic sheet over the adhesive surface to cover the wire and the first flexible plastic sheet,
• feeding the second flexible plastic sheet, the wire and first flexible plastic sheet under a roller, and
• pressing the second flexible plastic sheet into position under the roller and against the wire and the first flexible sheet to form a flexible wiring harness.