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I Molded covering systems for electrical wiring harnesses have been in production for European passenger car applications for over a decade and more recently used on North American heavy duty diesel engines for commercial vehicles. This proven technology has many advantages over traditional electrical wiring covering systems offering improved environmental performance, part-to-part consistency, and excellent aesthetics. Attachments can be molded into the wiring assembly. 2-D or 3-D molded wiring provides improved fit in vehicle installations and the potential for improved manufacturing automation. Current applications include chassis, engine, transmission, roof, and passenger compartment. The advantages and limitations of this technology will be discussed relative to the unique wiring harness manufacturing technology, harness design considerations and vehicle applications.

Polyurethane foam has been used in European vehicle applications as a covering for wiring harness assemblies for over a decade. During this period, the polyurethane chemistry has evolved to meet the stringent needs of the automotive engine compartment environment. This is a proven technology with many advantages over standard wire covering systems. In many cases, the improvements in environmental performance, part-to-part consistency, and aesthetics can be achieved while reducing part cost. 3-D molded wiring assemblies provide improved fit in vehicle installations. Yet, polyurethane foam over-molding technology is rarely utilized in North America for vehicle wiring applications. Polyurethane foam is also being used to cover electronic circuit assemblies in vehicular applications. As a further integration of component technologies, circuit assemblies are being built into wiring harnesses with the polyurethane foam being used as an environmental covering.