Product and method of manufacturing a product

Abstract

A method of manufacturing a product, the method comprising: forming a first layer to a shape of a mould, wherein the mould defines one or more grooves; placing one or more functional members in the one or more grooves; and placing a second layer over the first layer and the one or more functional members, such that the one or more functional members are enclosed within a sleeve formed by the first layer and the second layer.

Description

[0001] PRODUCT AND METHOD OF MANUFACTURING A PRODUCT

[0002] TECHNICAL FIELD

[0003] The disclosure relates to: a method of manufacturing a product; a product obtained using the method; a computer program comprising instructions, which, when executed, cause a computer to control a system to perform the method; and a system configured to perform the method.

[0004] BACKGROUND

[0005] A wiring harness is an assembly of wires or cables which can transmit signals and / or electrical power. The wires may be bound together in the wiring harness by a durable material, such as a polymer.

[0006] Currently, wiring harnesses are largely made by hand. Robotics can cut wire to length and add crimp terminations, but the laying of the cables and / or wires in the harness is almost exclusively done on a pin-board by skilled workers.

[0007] A typical process for manufacturing a wiring harness involves a series of steps. First, the wires are cut, stripped and crimped. Next, a 1 : 1 scale pin-board is used to organize wires into bundles which are held together with ties or sleeves. Then termination connectors (or plugs) are added. The wires or wire bundles are labelled and there is a quality control check. The harness is then packaged and shipped to the OEM. At the OEM the harness is installed into the system. Often further stand-offs and mounts and ties are needed to hold the wires in place. This is a complex, labour intensive and costly process that can result in manufacturing errors that require expensive product recalls.

[0008] Typically, wires in a wiring harnesses are bound together to form a bundle with a cross-section that is approximately circular. Recently, there has been an increased demand for flat wiring harnesses. In a flat wiring harness, a plurality of wires may be arranged such that, at a given point along the length of the wiring harness, the wires are in the same plane. Flat wiring harnesses may be desirable because they can be bent to conform to surfaces within a system. For example, a flat wiring harness may be able to bend around a body of a vehicle. This may mean that the wiring harness does not occupy excessive space within the system.

[0009] However, difficulties have been found in manufacturing flat wiring harness. For example, it may be difficult to maintain wires in a desired position before the wires are bound by the durable material. Consequently, where flat, flexible, conductive componentshave been desired, OEMs have often turned to flat, flexible PCBs. Flat flexible PCBs may comprise a flat sheet of copper machined and / or etched to form a plurality of conductive paths. The machined sheet of copper may be encapsulated in insulating layers. The result is a flexible component that is capable of transmitting signals and energy through a plurality of distinct conductive paths. This is a subtractive process that is well suited to problems where there are dense connections. However, this is wasteful when the connections are sparse. In such situations, additively placing wire is more efficient and cost effective.

[0010] Whilst the above background has focused on wiring harnesses, the problems identified are applicable to other functional members such as fibre optic members.

[0011] SUMMARY

[0012] It is an object of the disclosure to provide an efficient and reliable method for manufacturing flat products comprising functional members (e.g. flat wiring harnesses comprising wires).

[0013] According to a first aspect of the invention, there is provided a method of manufacturing a product, the method comprising: forming a first layer to a shape of a mould, wherein the mould defines one or more grooves; placing one or more functional members in the one or more grooves; and placing a second layer over the first layer and the one or more functional members, such that the one or more functional members are enclosed within a sleeve formed by the first layer and the second layer.

[0014] By providing the functional members in the one or more grooves, the functional members can be maintained securely in a desired position, even before the second layer is placed over the first layer and the one or more functional members to enclose the one or more functional members. This means that the method of manufacturing the flat product is made easier, and can be performed more quickly. Further, by placing the one or more functional members in the one or more grooves, the contact area between the one or more functional members and the first layer is increased. This results in stronger and / or more reliable adhesion between the one or more functional members and the first layer.

[0015] In an embodiment, the step of forming the first layer to the shape of the mould comprises vacuum moulding. Use of a vacuum moulding process may allow the first layer to be formed to the shape of the mould quickly, i.e. use of a vacuum moulding may decrease a time taken to manufacture the product. Vacuum moulding can also be automated.In an embodiment, the step of placing the second layer over the first layer and the one or more functional members comprises vacuum lamination. Vacuum lamination may be faster and more adaptable than alternatives, such as mechanical lamination. Vacuum lamination can also be automated.

[0016] In an embodiment, the method further comprises, after the placing the second layer over the first layer and the one or more functional members, removing first regions of the first layer and the second layer. This may allow a product with a desired shape to be obtained.

[0017] In an embodiment, the step of placing the one or more functional members in the one or more grooves is performed using a robotic tool. This allows the step of placing the one or more functional members to be automated. This means that the step can be performed more quickly (compared to, for example, a method in which the functional members are manually placed into the grooves by an operator).

[0018] In an embodiment, the method further comprises changing feed rates through each of a plurality of feed outputs as a function of time to ensure that lengths of the plurality of functional members output from the feed outputs is approximately equal to lengths of the plurality of channels. This may allow a feed head with a plurality of feed outputs to lay simultaneously a plurality of functional member along a curved path.

[0019] In an embodiment, a width of a groove is such that an interference fit is formed between the groove and a functional member that is placed into the groove. This means that the functional member is securely fixed in place by the groove, and so will not move out of a desired position.

[0020] In an embodiment, the mould comprises one or more accommodating portion features for forming one or more accommodating portions, and the method further comprises forming the one or more accommodating portions in the first layer. This allows one or more functional components (e.g. terminations, fixings and protection) to be installed in the product.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which corresponding reference symbols indicate corresponding parts.

[0023] Figure 1 depicts a flowchart showing a method of manufacturing a product.Figure 2 A depicts a 3 -dimensional representation of a mould which may be used in the method of Figure 1.

[0024] Figure 2B depicts a cross-sectional view of the mould depicted in Figure 2A.

[0025] Figure 3 A depicts a 3 -dimensional representation of the mould and the first layer. Figure 3B depicts a cross-sectional view of the mould and the first layer.

[0026] Figure 4 A depicts a 3 -dimensional representation of the mould, the first layer, and a plurality of functional members.

[0027] Figure 4B depicts a cross-sectional view of the mould, the first layer and the plurality of functional members.

[0028] Figure 5 depicts a feed head of a robotic tool and a plurality of functional members. Figure 6 depicts a 3 -dimensional representation of the mould, the first layer, the plurality of functional members and the second layer.

[0029] Figure 7 A depicts a 3 -dimensional representation of the mould, the first layer, the plurality of functional members and the second layer, after excess material has been removed.

[0030] Figure 7B depicts a cross-sectional view of the mould, the first layer, the plurality of functional members and the second layer, after the excess material has been removed.

[0031] Figure 8 A depicts a 3 -dimensional representation of the product, after the product has been removed from the mould.

[0032] Figure 8B depicts a cross-sectional view of the product, after the product has been removed from the mould.

[0033] Figure 9A depicts a method of manufacturing a product, in accordance with a first class of embodiment of the disclosure.

[0034] Figure 9B depicts a method of manufacturing a second type of product, in accordance with a second class of embodiment of the disclosure.

[0035] DETAILED DESCRIPTION

[0036] The present disclosure is directed to a method for manufacturing a product. The product is an assembly comprising one or more functional members. In an embodiment, the one or more functional members are arranged such that, at any given point along the length of the functional members, the functional members are approximately co-planar. The product may be substantially flat. The product may be a wiring harness. The wiring harness may be a flat wiring harness.Figure 1 depicts a flowchart showing steps of an example method for manufacturing a product. The method may comprise additional steps. Similarly, some of the steps included in the flowchart depicted in Figure 1 may not be essential.

[0037] In an embodiment, the method comprises a step SI of forming a first layer to a shape of a mould. The mould defines one or more grooves. The method further comprises a step S2 of placing one or more functional members in the one or more grooves. The method further comprises a step S3 of placing a second layer over the first layer and the one or more functional members, such that the one or more functional members are enclosed within a sleeve formed by the first layer and the second layer.

[0038] The method may further comprise a step S4 of removing first regions of the first layer and the second layer. The method may further comprise a step S5 of removing the product from the mould.

[0039] In an embodiment, the method is carried out in the order depicted in Figure 1, i.e. SI, then S2, then S3, then S4, then S5. If one or more steps were to be removed from the method, the method may still be performed in the same order, without the removed step. For example, if S4 were to be removed, the method may be performed in the following order: SI, then S2, then S3, then S5.

[0040] Figure 2 A depicts a 3 -dimensional representation of a mould 10 which can be used in the method. Figure 2B depicts a cross-sectional view of the mould 10 depicted in Figure 2A. The mould can be any suitable shape. In the embodiment depicted in Figures 2A and 2B, the mould is rectangular.

[0041] The mould 10 comprises one or more grooves, e.g. grooves 14a-d. In an embodiment, the grooves are formed in an upper surface 11 of the mould 10. The upper surface 11 may be a substantially flat, planar surface. The grooves 14a-d are cut into the upper surface 11 of the mould, such that lowermost points of each of the grooves 14a-d are beneath the upper surface 11.

[0042] The grooves 14a-d are each be configured to receive a functional member. The functional members are typically elongated members, with a large length and a small cross-sectional area. The profile of the grooves 14a-d may be comparable (i.e. similar to) the functional members. Thus, a cross-sectional area of the grooves 14a-d (and therefore a width and depth of the grooves) are relatively small, and a length of the grooves is relatively large. A width of a groove 14a-14d is a dimension in a direction that is parallel to the upper surface 11 of the mould 10 and perpendicular to a path of the groove 14a-14d.A depth of the groove is a dimension in a direction that is perpendicular to the upper surface 11 of the mould 10.

[0043] In some embodiments, each of the grooves 14a-d traverses the upper surface 11 of the mould 10. That is, a first end of a groove 14a-d is at a first edge of the upper surface 11 of the mould and a second end of the groove 14a-d is at a second edge of the upper surface 11. The first edge may be opposite to the second edge. Alternatively, the first edge may be adjacent to the second edge. Alternatively, the first and second ends of the grooves 14a-d may each be located at the same edge. A length of a groove 14a-14d may be a distance along a path of the groove 14a-14d between the first end of the groove 14a-14d and the second end of the groove 14a-14d.

[0044] The path of a groove 14a-d between the first end of the groove 14a-d and the second end of the groove 14a-d may take various forms. The paths of the grooves 14a-d may be linear. Alternatively, the paths of the grooves 14a-d may be curved, as depicted in Figures 2 A and 2B. The paths of the grooves 14a-d correspond to desired paths of respective functional members in the product.

[0045] The grooves may be grouped into one or more sets of grooves 12, 13, 14, 15. For example, the mould 10 comprises a first set of grooves 12, a second set of grooves 13, a third set of grooves 14 and a fourth set of grooves 15. Each set of grooves 12, 13, 14, 15 comprises one or more grooves. For example, the third set of grooves 14 comprises one or more first grooves 14a, one or more second grooves 14b, one or more third grooves 14c and one or more fourth grooves 14d. In the embodiment depicted in Figures 2A and 2B, the third set of grooves comprises one first groove 14a, one second groove 14b, four third grooves 14c and one fourth groove 14d.

[0046] In some embodiments, the paths of each of the grooves within a set of grooves may be substantially parallel. For example, in the third set of grooves 14, the path(s) of the one or more first grooves 14a, the path(s) of the one or more second grooves 14b, the path(s) of the one or more third grooves 14c and the path(s) of the one or more fourth grooves 14d are be substantially parallel. In some embodiments, a spacing between each of the grooves 14a, 14b, 14c, 14d may change over the lengths of the grooves 14a, 14b, 14c, 14d. In other words, a pitch of the grooves 14a, 14b, 14c, 14d may vary as a function of the axial position along the grooves 14a, 14b, 14c, 14d. As will be appreciated, this may mean that the paths of the grooves 14a, 14b, 14c, 14d are not exactly parallel.

[0047] In the embodiment depicted in Figures 2A and 2B, first ends of the grooves in the first set of grooves 12, first ends of the grooves in the second set of grooves 13, first endsof the grooves in the third set of grooves 14 and first ends of the grooves in the fourth set of grooves 15 are each be located in different portions of the edge of the mould. In the embodiment depicted in Figures 2A and 2B, second ends of the grooves in the first set of grooves 12, second ends of the grooves in the second set of grooves 13, second ends of the grooves in the third set of grooves 14 and second ends of the grooves in the fourth set of grooves 15 are each located in the same portion 16 of the edge of the mould. That is, at the second end of the first to fourth sets of grooves 12-14, the grooves in all of the first to fourth sets of grooves 12-14 may be substantially parallel.

[0048] The profile of the grooves 14a-14d, and particularly the width and depth of the grooves 14a-14d, may be configured so that each groove can receive a particular functional member corresponding to that groove. Thus, if the product that is to be manufactured using the mould will have functional members with differing cross-sections, the mould may have grooves 14a-14d with differing cross-sections. For example, in the third set of grooves 14, the first grooves 14a, second grooves 14b, third grooves 14c and fourth grooves 14d may be configured to receive functional members with different respective cross-sections. Consequently, the first grooves 14a, second grooves 14b, third grooves 14c and fourth grooves 14d may each have a different cross-section (i.e. a different width and depth).

[0049] The mould may comprise a plurality of vacuum openings 17. The vacuum openings 17 may be configured to allow a first vacuum force to be exerted on the first layer. Additionally, the vacuum openings may be configured to allow a second vacuum force to be exerted on the second layer. The system which performs the manufacture of the product may comprise a vacuum arrangement. The vacuum arrangement is configured to apply a vacuum pressure via the plurality of vacuum openings 17. The vacuum arrangement may comprise, for example, a dry vane vacuum pump. Instead of (or in addition to) the vacuum openings 17, the mould may be porous, such that the vacuum pressure can be applied through the main body of the mould 10. This may allow for uniform application of the vacuum pressure to the first layer and / or the second layer.

[0050] The mould 10 may further comprise a trim guide 18. The trim guide 18 may surround the sets of grooves 12-15. The trim guide 18 may have the same shape as the finished product. The trim guide 18 may be configured to guide a cutting tool in the step S4 of removing first regions of the first layer and the second layer. Specifically, the trim guide 18 may be configured to guide the cutting tool to follow a path along a boundary between the one or more first regions and the one or more second regions. Thus, the trimguide 18 may facilitate the removal of unneeded sections of the first layer and / or second layer to form a finished product with a target shape. Such a trim guide may be beneficial when the cutting is to be performed by hand. In some embodiments, the step S4 of removing first regions of the first layer and the second layer are performed by a machine which is controlled by a computer. In such embodiments, a trim guide may not be necessary.

[0051] The mould may be formed from any suitable material. The mould may be formed from a metal. A mould that is formed of a metal may be resistant to wear and able to withstand significant thermal loads.

[0052] The mould may be manufactured using any suitable technique. The mould may be manufactured using traditional casting and subtractive manufacturing techniques. Such techniques may allow the mould 10 to be formed from materials such as metal.

[0053] Alternatively, the mould may be manufactured using an additive manufacturing technique. For example, the mould 10 may be manufactured using VAT photopolymerisation, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination, material jetting, or directed energy deposition. Manufacturing the mould 10 using an additive manufacturing technique can reduce lead times in the manufacture of the mould. Further, manufacturing the mould 10 using an additive manufacturing technique means that the shape of the mould 10 can be quickly and easily changed. This allows the manufacturing process to be easily adapted to form products with different configurations. This means that the manufacturing process can be used to manufacture a range of types of products for a range of uses. Further, in some cases, manufacturing the mould 10 using an additive manufacturing technique can be cheaper than traditional methods. A method in accordance with the present disclosure may comprise a step of forming the mould 10 using the additive manufacturing technique.

[0054] In the step SI of forming the first layer 20 to the shape of the mould 10, the first layer 20 may be formed to the shape of the mould such that the first layer 20 takes the shape of the mould 10. Figure 3 A depicts a 3 -dimensional representation of the mould 10 and the first layer 20. Figure 3B depicts a cross-sectional view of the mould 10 and the first layer 20. Figures 3 A and 3B depict the product after the step SI of forming the first layer 20 to the shape of the mould 10. Figures 3 A and 3B depict the product before the step S2 of placing the one or more functional members in the one or more grooves 14a-d.The first layer 20 may be a film. The first layer 20 may be a sheet. Generally, the first layer 20 may be a broad, flat piece of material. A thickness of the first layer 20 is much less than any dimension of the first layer 20 perpendicular to the thickness.

[0055] In the step SI of forming the first layer 20 to the shape of the mould 10, portions of the first layer form to the one or more grooves, e.g. grooves 14a-d, such that one or more channels, e.g. channels 24a-d, are formed in the first layer 20. The channels 24a-d have the same shape as the grooves 14a-d. Thus, each channel 24a-d has a shape that is suitable to receive a functional member. In the embodiment depicted in Figures 3 A and 3B, a third set of channels 24 is formed by the third set of grooves 14. Specifically, a first channel 24a is formed where the first layer 20 is formed to the first groove 14a, a second channel 24b is formed where the first layer 20 is formed to the second groove 14b, four third channels 24c are formed where the first layer 20 is formed to the four third grooves 14c, and a fourth channel 24d is formed where the first layer 20 is formed to the fourth groove 14d. The same may occur for the first, second and fourth sets of grooves 12, 13, 15.

[0056] The first layer 20 may be formed from a material comprising a polymer. The first layer 20 may be formed from a material consisting essentially of a polymer. The first layer 20 may be formed from a material consisting of a polymer. The polymer may be a thermoplastic polymer. The polymer may comprise polyethylene terephthalate (PET), polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polymer may consist essentially of polyethylene terephthalate (PET) polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polymer may consist of polyethylene terephthalate (PET), polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polyethylene terephthalate may be biaxially-oriented polyethylene terephthalate. The polyethylene terephthalate may be Mylar®.

[0057] The first layer 20 may comprise a plurality of sub-layers. The plurality of sublayers may each be formed of the same material. Alternatively, the plurality of submaterials may be formed of different materials. The plurality of sub-layers may be laminated together.

[0058] The first layer 20 may be formed of a composite material. The first layer may comprise a textile component and a polymer component. For example, the first layer 20 may comprise a textile layer and a polymer layer. Alternatively, the first layer may be formed of a textile layer that has been impregnated with a resin. The textile may be anopen mesh fabric. Fibres in the textile may provide additional strength to the first layer 20, and improve tear-resistance.

[0059] The first layer 20 may be formed of a pre-impregnated (“pre-preg”) composite, i.e. a composite comprising structural fibres in a polymer matrix, wherein the polymer matrix has not been fully cured. The pre-preg may be a thermoplastic pre-preg, i.e. a pre-preg thermoplastic material that has been cooled but not cured. For example, the first layer 20 may be formed of pre-preg carbon fibre. The pre-preg composite may be flexible, and thus suitable for use in the method of the present disclosure. After the step S5 of removing the product from the mould, the pre-peg composite may be cured. This may mean that the first layer 20 is rigid, and thus able to protect the one or more functional members 34a-d.

[0060] In an embodiment, the step SI of forming the first layer 20 to the shape of the mould 10 may comprise exerting a first pulling force on the first layer 20 such that the first layer 20 is pulled onto the upper surface 11 of the mould 10. The step SI of forming the first layer 20 to the shape of the mould 10 may comprise vacuum forming. In this case, the first pulling force may be a force that is exerted by the vacuum arrangement. The vacuum forming process may be a standard vacuum forming process.

[0061] The step SI of forming the first layer 20 to the shape of the mould 10 may comprise one or more sub-steps. For, example, the step SI of forming the first layer 20 to the shape of the mould 10 may comprise one or more of the following steps.

[0062] (1 A) Clamping the first layer 20 within a frame.

[0063] (IB) Heating the first layer 20. The first layer 10 may be heated to a temperature which is similar to, and slightly greater than, the glass transition temperature (Tg) of the material from which the first layer is formed.

[0064] (IC) Heating the mould 10. The mould 10 may be heated to a temperature of which is similar to, and slightly greater than, the glass transition temperature (Tg) of the material from which the first layer is formed .

[0065] (ID) Moving the first layer 20 within the frame towards the mould 10, and / or moving the mould 10 towards first layer 20 within the frame .

[0066] (IE) Applying the first pulling force to draw the first layer 20 over the upper surface 11 of the mould 10.

[0067] Heating the first layer 20 and / or the mould 20 (steps IB and / or 1C) can be performed using any suitable heating means. For example, heating of the first layer 20 and / or the mould 20 may be performed using infrared heating elements configured to generate and direct infrared radiation towards the first layer 20 and / or the mould 10. Thefirst layer 20 may be heated uniformly over its surface and throughout its thickness.

[0068] Heating the mould 10 and / or the first layer 20 may improve the forming of the first layer 20 to the shape of the mould.

[0069] In the case that first layer 20 is formed of a pre-preg composite, the mould 10 may be heated for the following reasons. If the pre-preg composite is a thermosetting pre-preg composite (e.g. a pre-preg composite comprising an epoxy as well as carbon fibres, glass fibres and / or aramid fibres), the mould 10 may be heated such that the thermosetting prepreg composite rapidly cures when the first layer is laid onto the mould 10. If the pre-preg composite is a thermoplastic pre-preg composite (e.g. polypropylene and / or polyethylene as well as carbon fibres, glass fibres and / or aramid fibres), the mould 10 may be heated such that the thermoplastic pre-preg composite softens upon contact with the mould 10, thus improving the extent to which the first layer 20 forms to the shape of the mould 20.

[0070] When the first layer 20 is initially clamped in the frame (1 A), the first layer 20 may be spaced apart from the mould 10 in a vertical direction. This may be such that the first layer 20 is above the mould 10. Moving the first layer 20 within the frame towards the mould 10 (step ID) may comprise moving the first layer 20 within the frame downward. Moving the mould 10 towards the first layer 20 within the frame (step ID) may comprise moving the mould 10 upward. Performing step ID may cause the first layer 20 to come into contact with the upper surface 11 of the mould 10. After the first layer 20 comes into contact with the upper surface 11 of the mould 10, the first layer 20 within the frame may continue to move downward and / or the mould 10 may continue to move upward. This may mean that the first layer 20 is deformed by the mould, i.e. that the mould 10 presses into the first layer 20.

[0071] The thickness of the first layer 20 is not particularly limited. The thickness of the first layer 20 may be such that the first layer 20 is suitable to be formed to the shape of the mould 10 by vacuum forming. The thickness of the first layer 20 may be such that the first layer 20 can provide effective protection to the functional members. For example, the first layer 20 may have a thickness that is less than 10 mm, preferably less than 1 mm, further preferably less than 0.5 mm, and further preferably less than 0.25 mm. The first layer may have a thickness that is greater than 0.01 mm, preferably greater than 0.02 mm, and further preferably greater than 0.05 mm.

[0072] In some embodiments, the first pulling force in the step SI of forming the first layer 20 to the shape of the mould 10 may not comprise vacuum moulding. In some embodiments, the step SI of forming the first layer 20 to the shape of the mould 10 maycomprise exerting a compressive force on the first layer 10. The compressive force may be in addition to, or instead of, the exertion of the first pulling force on the first layer 20. The compressive force may be applied by creating a region of positive air pressure above the first layer 20. The compressive force may arise as a result of blowing gas (e.g. air) at the first layer 20. That is, the step SI of forming the first layer 20 to the shape of the mould 10 may comprise blow moulding. Alternatively, the compressive force may be provided by a roller which is rolled over the first layer 20 once the first layer 20 has been laid onto the mould 10. The roller may be heated to improve the extent to which the first layer 20 forms to the shape of the mould 10.

[0073] Figure 4 A depicts a 3 -dimensional representation of the mould 10, the first layer 20, and a plurality of functional members 34a-d. Figure 4B depicts a cross-sectional view of the mould 10, the first layer 20 and the plurality of functional members 34a-d. Figures 4A and 4B depict the product after the step S2 of placing the one or more functional members 34a-d in the one or more grooves 14a-d. Figures 4A and 4B depict the product before the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members 34a-d.

[0074] The step S2 of placing the one or more functional members 34a-d in the one or more grooves 14a-14d comprises placing the one or more functional members 34a-d in the one or more channels 24a-24d formed in the first layer 20. Placing the one or more functional members 34a-d in the one or more channels 24a-24d formed in the first layer 20 may comprise laying the one or more functional members 34a-d in the one or more channels 24a-d.

[0075] By providing the functional members in the one or more grooves 14a-d, the functional members 34a-d can be maintained securely in a desired position, even before the second layer 40 is placed over the first layer 20 to enclose the one or more functional members 34a-d. This means that the method of manufacturing the flat product is made easier, and can be performed more quickly. Further, by placing the one or more functional members 34a-d in the one or more channels 24a-d formed by the one or more grooves 14a-d, the contact area between the one or more functional members 34a-d and the first layer is increased (relative to the case that a functional member is placed onto a first layer 20 which is completely flat, i.e. which does not contain channels 24a-d). This results in the one or more functional members 34a-d being held in position more strongly and / or more reliably.A width of a groove 14a-d may be such that an interference fit is formed between the groove 14a-d and a functional member 34a-d that is placed into the groove 14a-d. The interference fit may also be described as being between a channel 24a-d and the functional member 34a-d. An interference fit may also be referred to as a press fit or a friction fit. When a functional member 34a-d is placed in a channel 24a-d, the functional members 34a-d and / or the first layer 20 and / or the mould 10 may elastically deform in a direction that is substantially perpendicular to the path of the functional member 34a-d and parallel to the upper surface. Consequently, a force may be exerted on the functional member 34a-d in a radially inward direction that is substantially parallel to the upper surface 11. As a result, the functional member 34a-34d may be held in place within the groove 14a-d.

[0076] To achieve an interference fit between a groove 14a-d and a functional member 34a-d that is placed into the groove 14a-d, a width of the groove may be similar to, but slightly less than, the sum of the diameter of the functional member 14a-d that is placed in the groove and twice the thickness of the first layer 20. For example, the width of the groove may be between 90% and 95% of the sum of the diameter of the functional member 14a-d that is placed in the groove and twice the thickness of the first layer 20, optionally between 95% and 99.9% of the sum of the diameter of the functional member 14a-d that is placed in the groove and twice the thickness of the first layer 20.

[0077] Due to the interference fit between the plurality of functional members 34a-d and the plurality of grooves 14a-d, a vertical force (i.e. a force that is perpendicular to the upper surface 11 and going towards the mould 10) may be applied on the functional members 34a-d to push the functional members 34a-d into the grooves 14a-d.

[0078] In some configurations, one functional member 34a-d is placed in each channel 24a-d. For example, in the third set of channels 24: a first functional member 34a is placed in the first channel 24a; a second functional member 34b is placed in the second channel 24b; a third functional member 34c is placed in each of the third channels 24c; and a fourth functional member 34 is placed in the fourth channel 24d. A channel 24a-d and a functional member 34a-d placed in the channel 24a-d have corresponding sizes.

[0079] The one or more functional members 34a-d may comprise one or more conductive members. The one or more conductive members may be wires. The wires may be coated. That is, conductive metal portions of each of the wires may be surrounded by a protective and / or insulating material. Alternatively, the wires may be bare. That is, conductive metal portions of each of the wires may not be surrounded by a protective and / or insulativematerial. That is, conductive metal portions of each of the wires may be exposed. The one or more conductive members may comprise a combination of coated and bare wires.

[0080] Additionally or alternatively, the one or more functional members 34a-d may comprise one or more fibre optic members. The fibre optic members may be fibre optic cables.

[0081] Additionally or alternatively, the one or more functional members 34a-d may comprise one or more structural members. The one or more structural members may comprise one or more ropes. The one or more structural members may comprise one or more strings. The one or more structural members may comprise one or more structural fibres. The one or more structural members may comprise one or more structural filaments.

[0082] Additionally or alternatively, the one or more functional members 34a-d may comprise flexible piping (i.e. conduits for the passage of any fluids therethrough).

[0083] Additionally or alternatively, the one or more functional members 34a-d may comprise hydraulic tubing or hydraulic lines (i.e. conduits for the passage of hydraulic fluid therethrough). Additionally or alternatively, the one or more functional member 34a-d may comprise pneumatic tubing or pneumatic lines (i.e. conduits for the passage of pressurised air therethrough). Additionally or alternatively, the one or more functional member 34a-d may comprise vacuum tubing or vacuum lines.

[0084] A cross-section of one or more of the functional members 34a-d may be circular, rectangular or, generally, polygonal. One or more of the functional members 34a-d may be helical.

[0085] In some embodiments, two or more functional members 34a-d may be placed in a single groove 14a-d. For instance, a twisted pair of wires may be placed into a single groove 14a-d.

[0086] The step S2 of placing the one or more functional members 34a-d in the one or more grooves 14a-d may be performed using a robotic tool. The robotic tool may be automated. The robotic tool comprises a feed head 50. Figure 5 depicts a feed head 50 of a robotic tool and a plurality of functional members 37a-e. The feed head 50 may comprise one or more feed units 51a-e. Each feed unit 51a-e may have a feed output 52a-e. Each of the feed units 51a-e may be configured to provide a functional member 37a-e through the feed output 52a-e. The feed units may comprise one or more rollers (not shown) or belts (not shown). The rollers or belts may be configured to exert a force on thefunctional members 37a-e such that they are drawn from where they are stored (e.g. a spool) to be output at the feed output 52a-e.

[0087] In some embodiments, the step S2 of placing the one or more functional members 34a-d into the one or more grooves 14a-d may further comprise pushing the one or more functional members 34a-d into the one or more grooves 14a-d. The one or more functional members 34a-d may be pushed into the one or more grooves 14a-d using, for example, one or more compression rollers (not shown). The one or more compression rollers may be a part of, or coupled to, the feed head 50. The one or more rollers may follow the feed units 51a-e (i.e. the one or more rollers may be behind the feed units 51a-e) such that, after the functional members 37a-e are provided through the feed outputs 52a-e, the functional members 37a-e are pushed into the or more grooves 14a-d by the one or more compression rollers. In some embodiments, there may be a plurality of compression rollers, with one compression roller for each of the feed units 51a-e. In such embodiments, the compression rollers may be movable relative to the feed head 50, such that the spacing of the compression rollers can be changed in accordance with any change in the spacing of the functional members 37a-e. In other embodiments, a single compression roller may be provided for all of the feed units 51a-e.

[0088] The feed head 50 may be movable in a horizontal plane. For example, the feed head 50 may be movable in an x-direction and a y-direction, wherein each of the x-direction and the y-direction are substantially parallel to the upper surface 11 of the mould 10, and the x-direction is perpendicular to the y-direction. To be movable in the x-direction and the y-direction, the feed head 50 may be mounted on an XY stage.

[0089] The feed head may be rotatable around a vertical axis. The vertical axis may be substantially perpendicular to the upper surface of the mould 10. The vertical axis may pass through a middle portion of the feed head 50. The feed head may be movable in a vertical direction. The feed head may be rotatable around the x-direction and / or the y-direction.

[0090] The step of placing the one or more functional members in the one or more grooves may comprise simultaneously placing a plurality of functional members in a plurality of grooves using the robotic tool. To place a plurality of functional members in a plurality of grooves, the feed head 50 may comprise a plurality of feed head units 51a-e. For example, in the embodiment depicted in Figure 5, the feed head 50 comprises five feed head units 5 la-e. The type of functional member that is laid by each feed head unit 5 la-e may be individually controllable. That is, one of the feed head units 5 la-e may lay a different typeof functional member to other feed head units 51a-e. For example, first, second and third feed head units 51a-c may lay a wire with a first diameter 37a-c, a fourth feed head unit 5 Id may lay a wire with a second diameter 37d, and a fifth feed head unit 5 le may lay an optical fibre 37e.

[0091] During operation, the feed head 50 may be moved along a path in the x-y plane that is the same as the paths of the grooves into which the functional members 37a-e are being placed. The plurality of feed outputs 52a-e may be aligned linearly. During operation, the plurality of feed outputs 52a-e may be aligned along a direction that is substantially perpendicular to a direction of travel of the feed head 50. Separations between the feed outputs 52a-e may be substantially the same as respective separations between the grooves into which the functional members 37a-e are being placed.

[0092] If the paths of the grooves are not linear, the feed head 50 may rotate to ensure that the feed outputs 52a-e remain aligned perpendicularly to the direction of travel when the direction of travel changes.

[0093] The rate at which a functional member is fed out of a feed output may be referred to as a feed rate. The feed rates of the plurality of feed outputs 52a-e may be independently controllable. That is, a first feed rate of the first feed output 52a may be different to a second feed rate of the second feed output 52b, a third feed rate of a third feed output 52c, etc. The feed head 540 may be configured such that the feed rates of the feed outputs 52a-e can be changed. The feed head 50 may be configured such that the feed rates of the plurality of feed outputs 52a-e can be changed independently of each other. The feed head 50 may be configured to change the feed rates through each of the feed outputs 52a-e as a function of time. This may ensure that lengths of the plurality of functional members 37a-e output from the feed outputs 52a-e are approximately equal to the lengths of the corresponding channels.

[0094] In the embodiment depicted in Figure 5, the paths of the plurality of functional members 37a-e begin in the y-direction, turn anticlockwise, proceed in a straight line, turn clockwise, and then proceed in a straight line in the y-direction. When the feed head 50 is turning a corner, it may be necessary for the feed rate of a feed output on the inside of the comer to be slower than the feed rate of a feed output on the outside of the comer. This may be because the length of a path on the outside of a corner is longer than a length of a path on the inside of a corner. For example, for the clockwise turn depicted in Figure 5, the feed rate through the fifth feed output 52e may be slower than the feed rate through thefirst feed output 52a. When the paths of the grooves are straight lines, the feed rate through each feed output 52a-e may be substantially the same.

[0095] The feed rates may be controlled by a controller. The controller may determine the feed rates required for each of the feed outputs 52a-e from the path travelled by the feed head 50. Additionally or alternatively, the feed rates through the feed outputs 52a-e may be made to differ by a mechanical means. The mechanical means may be a differential. The differential may be integrated in the feed head 50.

[0096] A feed head 50 with a plurality of feed outputs may lay a set of functional members in a set of grooves simultaneously. For example, in the embodiment depicted in Figures 4A and 4B, the feed head may lay the functional members 34a-34d simultaneously.

[0097] In an embodiment, the method comprises bonding the one or more functional members 35a-d to the first layer 20. Bonding the one or more functional members 35a-d to the first layer 20 may be performed using any suitable technique. For example, bonding the one or more functional members 35a-d to the first layer 20 may comprise heat bonding and / or use of an adhesive. In the case that heat bonding is used, heat may be applied to the one or more functional members 34a-d and the first layer 20. In the case that an adhesive is used, an adhesive may be applied to the one or more channels 24a-d formed in the first layer 20 before the one or more functional members 24a-d are laid in the one or more channels 24a-d. Additionally or alternatively, an adhesive may be applied to the one or more functional members 24a-d before and / or during the step of laying the one or more functional members 34a-d in the one or more channels 24a-d. In an embodiment, an adhesive is applied to substantially all of the first layer 20 (i.e. in the one or more channels 24a-d and around the one or more channels 24a-d). In this case, the adhesive that is applied to the first layer 20 bonds the one or more functional members 34a-d to the first layer 20 and bonds the second layer 40 to the first layer 20.

[0098] Figure 6 depicts a 3 -dimensional representation of the mould 10, the first layer 20, the plurality of functional members 34a-d and a second layer 40. Figure 6 depicts the product after the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members 34a-d. Figure 6 depicts the product before the step S4 of removing first regions of the first layer and the second layer.

[0099] Like the first layer 20, the second layer 40 may be a film. The second layer 40 may be a sheet. Generally, the second layer may be a broad, flat piece of material.

[0100] The second layer 40 be formed from a material comprising a polymer. The second layer may be formed from a material consisting essentially of a polymer. The second layermay be formed from a material consisting of a polymer. The polymer may comprise polyethylene terephthalate, polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polymer may consist essentially of polyethylene terephthalate, polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polymer may consist of polyethylene terephthalate, polyurethane, polyethylene, polypropylene, vinyl, polyester, polythene or a polyamide. The polyethylene terephthalate may be biaxially-oriented polyethylene terephthalate. The polyethylene terephthalate may be Mylar®.

[0101] The second layer 40 may comprise a plurality of sub-layers. The plurality of sublayers may each be formed of the same material. Alternatively, the plurality of submaterials may be formed of different materials. The plurality of sub-layers may be laminated together.

[0102] The second layer 40 may be formed of a composite material. The first layer may comprise a textile component and a polymer component. For example, the second layer 40 may comprise a textile layer and a polymer layer. Alternatively, the first layer may be formed of a textile layer that has been impregnated with a resin. The textile may be an open mesh fabric. Fibres in the textile may provide additional strength to the second layer 40, and improve tear-resistance.

[0103] The second layer 40 may be formed of a pre-impregnated (“pre-preg”) composite, i.e. a composite comprising structural fibres in a polymer matrix, wherein the polymer matrix has not been fully cured. The pre-preg may be a thermoplastic pre-preg, i.e. a prepreg thermoplastic material that has been cooled but not cured. For example, the second layer 40 may be formed of pre-preg carbon fibre. The pre-preg composite may be flexible, and thus suitable for use in the method of the present disclosure. After the step S5 of removing the product from the mould, the pre-peg composite may be cured. This may mean that the second layer 40 is rigid, and thus able to protect the one or more functional members 34a-d. The description provided above in relation to the heating of the first layer 20 and / or the mould 10 when the first layer 20 is formed of a pre-preg composite applies equally to the case where the second layer 40 is formed of a pre-preg composite.

[0104] The second layer 40 may be formed from the same material as the first layer.

[0105] In an embodiment, the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members may comprise pulling the second layer 40 onto the first layer 20. Pulling the second layer 40 onto the first layer 20 may comprise applying a second pulling force on the second layer 40 using the vacuum arrangement. Sothat the vacuum arrangement can be used to apply the second pulling force on the second layer 40, the method may further comprise creating one or more holes (not shown) in the first layer 20. The one or more holes created in the first layer 20 may align with the vacuum holes 17 in the mould 10. The holes may be formed using any suitable method. A step of creating holes in the first layer 20 may be performed after the first layer 20 has been formed to the shape of the mould 10 and before the second layer 40 is placed over the first layer 20 and the one or more functional members 34a-d.

[0106] In an alternative embodiment, the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members 34a-d comprises vacuum lamination. In this case, the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members 34a-d comprises one or more of the following steps:

[0107] (3 A) Placing the second layer 40 on top of the first layer 20 and the one or more functional members 34a-d.

[0108] (3B) Positioning the mould 10, the first layer 20, the one or more functional members 34a-d and the second layer 40 in a frame (not shown). A vacuum arrangement is also provided within the frame.

[0109] (3C) Placing a membrane (not shown) over the second layer 40 in the frame, such that the membrane forms a seal with the frame. The placing the membrane over the second layer may mean that the frame and the membrane together form a sealed area, in which the mould 10, the first layer 20, the one or more functional members 34a-d and the second layer 40 are disposed, along with the vacuum arrangement.

[0110] (3D) Reducing the pressure within the sealed area by extracting air, using the vacuum arrangement. This may mean that air is extracted from between the first layer 20 and the second layer 40, and the second layer 40 is pulled down onto the first layer 20. This may also mean that the membrane is pulled down onto the second layer 40, such that the membrane pushes the second layer 40 onto the first layer 20.

[0111] In an alternative embodiment, the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members may comprise pushing the second layer 40 onto the first layer 20. For example, the second layer 40 may be laid over the first layer 20 and the one or more functional members 34a-d. A compressive force may then be applied to the second layer 40 such that the second layer 40 is pushed down onto the first layer 20 and the one or more functional members 34a-d. The compressive force may beapplied using a roller. Additionally or alternatively, the compressive force may be applied by creating a positive air pressure above the second layer 40. In other words, the compressive force may be applied by blowing air at the second layer 40.

[0112] In an alternative embodiment, the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members may comprise heating the second layer 40 such that the second layer 40 shrinks, thus encapsulating the functional members 34a-d. In this step, the first layer 20 may also be heated so that the first layer 20 also shrinks to encapsulate the functional members 34a-d.

[0113] In an embodiment, the method further comprises bonding the second layer 40 to the first layer 20. The bonding the second layer 40 to the first layer 20 may be a part of the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members 34a-d. Alternatively, the bonding the second layer 40 to the first layer 20 may be independent of the step S3 of placing the second layer 40 over the first layer 20 and the one or more functional members, being performed before or after the placing the second layer 40 over the first layer 20 and the one or more functional members.

[0114] Bonding the second layer 40 to the first layer 20 may comprise thermal bonding. Thermal bonding may be performed by heating the second layer 40 and / or the first layer 20 after the second layer 40 and the first layer 20 have come into contact. Alternatively, bonding the second layer 40 to the first layer 20 may comprise use of an adhesive. The adhesive may be applied to the first layer 20 before the second layer 40 is placed over the first layer 20 and the one or more functional members 34a-d.

[0115] To improve the strength of the bond formed by the adhesive between the first layer 20 and the second layer 40, and / or to improve the strength of the bond formed by the adhesive between the first layer 20 and the one or more functional members 34a-d and / or to improve the strength of the bond formed by the adhesive between the one or more functional members 34a-d and the second layer 40, heat may be applied to the first layer 20 and / or the one or more functional members 34a-d and / or the second layer 40.

[0116] Any suitable adhesive may be used. In some embodiments, PSAs (pressure sensitive adhesives) may be sued. For instance, acrylic-based PSAs, e.g. 3M™ VHB™, may be used. WBPSAs (water based PSAs) or silicone based PSAs may also be used. Thermoplastic laminate weld layers may also be used, wherein the thermoplastic comprises one or more of polyethylene (PE), ethylene vinyl acetate (EVA), ethyl vinyl alcohol (EVOH), poly vinyl butyral (PVB), or a polyamide (PA). Hot melt adhesives, e.g. acrylate, polyvinyl chloride (PVC), polyethylene tetrafluoride (PET), thermoplasticpolyurethane (TPU), polyurethane (PUR), polyamide (PA), ethylene vinyl acetate (EVA), thermoplastic rubber (TPR), amorphous poly-olefins (APOs / APAOs), methyl propanediol (MPO) and thermoplastic elastomers (TPE). Epoxies, thermosetting polymers (e.g. thermosetting polymers that can be cured using heat, NIR radiation, UV radiation or an electron beam), and silicones may also be used.

[0117] In some embodiments, functional members may be adhered to a 3M™ VHB™ continuous film. In some embodiments, a functional member may be co-extruded with, pultruded alongside, or coated with, a thermoplastic polymer (e.g. PET, PE, or PA) or a hot melt adhesive (e.g. APAO).

[0118] In some embodiments, functional members may be laid onto beads of adhesive / polymer. In such embodiments, the functional members may be heated (in which case the glue / adhesive may be cold), or the glue / adhesive may be heated (in which case the functional members may be cold). In other embodiments, functional members may be laid onto beads of resin, which are then cured, e.g. using UV radiation.

[0119] In some embodiments, thermal bonding method, photo bonding methods, and / or cutting methods may be used in the bonding steps of the present invention. Such methods may comprise use of a laser and / or infrared radiation, use of a hot knife, hot roller, or hot wire, use of ultrasonic welding, and / or use of solvent welding.

[0120] To promote bonding, plasma activation, corona treatment, UV treatment and / or flame treatment may be used on the layers 20, 40 to increase surface energy (e.g. by adding OH / ON groups).

[0121] In an embodiment, the first layer 20 comprises one or more first regions 20a and one or more second regions 20b. Similarly, the second layer 40 may comprise one or more first regions 40a and one or more second regions 40b. The one or more first regions 20a of the first layer 20 may correspond to the one or more first regions 40a of the second layer 40, and the one or more second regions 20b of the first layer 20 may correspond to the one or more second regions 40b of the second layer 40. That is, when the second layer 40 has been placed over the first layer 20, the first regions 40a of the second layer 40 may align with the first regions 20a of the first layer 20, and the second regions 40b of the second layer 40 may align with the second regions 20b of the first layer 20. The one or more first regions 20a, 40a of the first layer 20 and the second layer 40 may be undesired regions. That is, the or more first regions 20a, 40a of the first layer 20 and the second layer 40 may be excess material. The one or more second regions 20b, 40b of the first layer 20 and the second layer 40 may be desired regions.Figure 7 A depicts a 3 -dimensional representation of the mould 10, the first layer 20, the plurality of functional members 34a-d and the second layer 40, after excess material has been removed. Figure 7B depicts a cross-sectional view of the mould 10, the first layer 20, the plurality of functional members 34a-d and the second layer 40, after the excess material has been removed. Figures 7A and 7B depict the product after the step S4 of removing the first regions of the first layer 20 and the second layer 40. Figures 7A and 7B depict the product before the step S5 of removing the product from the mould 10.

[0122] The product P may have a target shape. The target shape may be a shape in a plane which is parallel to the upper surface 11 of the mould 10 when the product P is located on the mould 10. The removal of the first regions 20a, 40a of the first layer 20 and the second layer 40 may be performed such that the second regions 20b, 40b remain. The removal of the first regions 20a, 40a (i.e. the undesired regions) of the first layer 20 and the second layer 40 may be such that the target shape is obtained.

[0123] The one or more second regions 20b, 40b of the first layer 20 and the second layer 40 may surround the one or more functional members 34a-d. As explained above, a functional member 34a-d may follow a path from a first end to a second end. A second region 20b, 40b may follow the path of a functional member. A distance between a functional member 34a-d and an edge of a second region in a direction that is perpendicular to the path may be a threshold distance. The first regions 20, 40a of the first layer 20 and the second layer 40 may comprise regions in which the distance to a functional member is greater than the threshold distance. The threshold distance may be sufficiently large such that, when the first regions 20a, 40a of the first layer and the second layer 40 are removed, enough material is maintained for the functional members 34a-d to have sufficient protection. Where a plurality of functional members 34a-d are provided in a set 34, a second region may surround the set of functional members 34. The second region may extend outward from the set of functional members from outermost functional members 34a, 34d for the threshold distance.

[0124] The removing the first regions 20a, 20b of the first layer 20 and the second layer 40 may be performed using any suitable method. For example, the removing the first regions 20a, 40a of the first layer 20 and the second layer 40 may comprise laser texturing.

[0125] Additionally or alternatively, the removing the first regions 20a, 40a of the first layer 20 and the second layer 40 may comprise mechanical cutting. Additionally or alternatively, removing the first regions 20a, 40a of the first layer 20 and the second layer 40 may comprise machining or profiling. In some embodiments, ultrasonic and / or thermal cuttingmay be used to remove the first regions 20a, 40a of the first layer 20 and the second layer 40. By using ultrasonic and / or thermal cutting and / or laser cutting, the first regions 20a, 40a of the first layer 20 and the second layer 40 may be removed and the first layer 20 and second layer 40 joined (e.g. welded) together simultaneously.

[0126] In the case that mechanical cutting is used to remove the first regions 20a, 40a of the first layer 20 and the second layer 40, the mould 10 may further comprise the trim guide 18, and the cutting may be performed along the trim guide 18. In the case that the first regions 20a 40a of the first layer 20 and the second layer are removed using a machine which is controlled by a computer, a trim guide may not be required. The trim guide 18 may be present if the cutting is to be performed by hand.

[0127] In the method described above, the step S4 of removing first regions 20a, 20b of the first layer 20 and the second layer 40 has been described as a step in which a cutting process is performed on the first layer 20 and the second layer 40 simultaneously, after steps SI to S3. However, this is not essential. In some embodiments, the first layer 20 and / or the second layer may be pre-cut prior to being laid onto the mould 10. In such an embodiment, it may not be necessary to perform the step S4 of removing first regions of the first layer 20 and the second layer 40 to arrive at a product P having the desired shape. In other embodiments, the first regions 20a of the first layer may be removed in a step performed after the step SI of forming the first layer 20 to the shape of the mould 10 and before the step of placing the second layer 40 over the first layer 20 and the one or more functional members.

[0128] Figure 8A depicts a 3-dimensional representation of the product P. Figure 8B depicts a cross-sectional view of the product P. Figures 8A and 8B depict the product after the step S5 of removing the product from the mould 10.

[0129] After the steps described above, a bonding means (e.g. an adhesive) may be deposited on an outer surface of the first layer 20 or the second layer 40. This bonding means may be used to secure the product P to the device in which it is to be installed.

[0130] Figure 9A depicts a method of manufacturing a product in accordance with a first class of embodiment. In Figure 9A: (A) depicts the mould 10 and the first layer 20 after the step of forming the first layer 20 to the mould 10; (B) depicts the mould 10, first layer 20 and functional members 38a, 38b after the step of placing the functional members 38a, 38b in the grooves; (C) depicts the mould 10, the first layer 20, functional members 38a, 38b and the second layer 40 after the step of placing the second layer 40 over the first layer20 and the functional members 38a, 38b; and (D) depicts the product P after the product P has been removed from the mould 10.

[0131] The first layer 20 may be bonded to the second layer 40 at an interface. The interface may locally define an interface plane I.

[0132] In the first class of embodiment, the method is performed such that the functional members 38a, 38b are located on one side of the interface plane I. This may mean that the entirety of the functional members 38a, 38b are below the second layer 40. An uppermost point of the functional members 48a, 48b may be tangential to the interface plane I (and therefore the second layer 40). This may mean that the second layer 40 is completely flat. When the functional members 38a, 38b are located on one side of the interface plane I, a depth of a channel 28a may be approximately equal to a diameter of the functional member 38a which is to be placed in the channel 28a. This may mean that a depth of a groove is approximately equal to the sum of the diameter of the functional member that is placed in the groove and a thickness of the first layer 20.

[0133] Figure 9B depicts a method of manufacturing a second type of product, in accordance with a second class of embodiment. In Figure 9B: (A) depicts the mould 10 and the first layer 20 after the step of forming the first layer 20 to the mould 10; (B) depicts the mould 10, first layer 20 and functional members 39a, 39b after the step of placing the functional members 39a, 39b in the grooves; (C) depicts the mould 10, the first layer 20, functional members 39a, 39b and the second layer 40 after the step of placing the second layer 40 over the first layer 20 and the functional members 39a, 39b; and (D) depicts the product P after the product P has been removed from the mould 10.

[0134] In the second class of embodiment, the method is performed such that the one or more functional members 39a, 39b extend across the interface plane I. For example, the method may be performed such that a plane bisecting a cross-section of the one or more functional members 39a, 39b is approximately co-planar with the interface plane I.

[0135] So that the plane bisecting the cross-section of the one or more functional members 39a, 39b is approximately co-planar with the interface plane I, a depth of a channel 29a may be approximately equal to half the diameter of a functional member 39a that is placed in the channel 29a. This may mean that the groove which forms the channel 29a has a depth that is approximately equal to the sum of half the diameter of a functional member 39a that is placed in the channel 29a and a thickness of the first layer 20.

[0136] Providing a product P where the one or more functional members 39a, 39b extend across the interface plane I may mean that the stiffness of the product P is substantially thesame in the following two cases: (i) “upward bending” where the first layer 20 is in tension and the second layer 40 is in compression; and (ii) “downward bending” where the first layer 20 is in compression and the second layer 40 is in tension.

[0137] In another embodiment (not shown), the one or more grooves is or are formed on a non-planar surface of the mould 10. For example, a height of the mould 10 in a vertical direction may be a function of position in the horizontal plane. A profile of the non-planar surface may correspond to a non-planar target profile (e.g. a curved target profile) for the product.

[0138] The method may further comprise a step of providing an insulating layer (not shown). The insulating layer may be provided (not shown) to the first layer 20 (i.e. on top of the first layer 20) before the step of placing the one or more functional members 34a-d in the one or more grooves 14a-d. Additionally or alternatively, the method may further comprise a step of providing an insulating layer (not shown) to the first layer 20 after the step S2 of placing the one or more functional members in the grooves (i.e. on top of the first layer 20 and the one or more functional members 34a-d). A shielding layer or a structural layer may be provided in addition to or instead of the insulating layer. The shielding layer may be an electromagnetic (EM) shielding layer. That is, the shielding layer may reduce or block an electromagnetic field. The shielding layer may comprise a conductive material. For example, the shielding layer may comprise a metal layer. For example, a shielding layer may comprise an aluminium coating. Additionally or alternatively, the shielding may comprise a conductive mesh formed therein.

[0139] The method may comprise bending the product P. Bending the product P may be performed after the product P has been removed from the mould 10. Bending of the product 10 may be performed to achieve a target shape. Alternatively, bending the product may define a weak-point in the product. This may mean that, if a similar force is applied to the product, the product will bend again at the weak-point. This may make subsequent steps of a manufacturing method (e.g. assembling the product P into a system) easier.

[0140] The mould 10 may further comprise one or more bend portion features (not shown). The one or more bend portion features may be for forming one or more bend portions in the first layer 20 and the second layer 40. The one or more bend portions may be configured to facilitate bending at the bend portions. Bend portion features may be recesses or ridges in the mould 10.

[0141] The method may further comprise forming the one or more bend portions in the product P, i.e. in the first layer 20 and the second layer 40. This step may compriseforming portions of the first layer 20 and / or the second layer 40 to the bend portion features in the mould 10. If a step of bending is performed after the product P has been removed from the mould 10, the bending may be performed at the one or more bend portions.

[0142] In an embodiment, the method further comprises a step of placing one or more functional components within the sleeve formed by the first layer 20 and the second layer 40. The functional components may differ from the functional members in that they are not elongated to the same extent. For example, a functional component may have dimensions (i.e. a height, width and depth) which are of the same order of magnitude. One or more of the further functional components may be configured to be connected to the one or more of the functional members 34a-d. For example, one or more of the functional members 34a-d may be a termination. A termination may be a component which allows a functional member to be connected to another component. For example, if a functional member is a wire, a termination may allow the wire to be connected to a wire that is not enclosed within the first layer 20 and the second layer 40. A termination may be, for example, a connector, a switch or a terminal. Additionally or alternatively, one or more of the functional components may be fixings. Examples of the fixings are nuts, threaded holes and plugs. Additionally or alternatively, one or more functional components may be protective components.

[0143] The one or more functional components may be placed on the first layer 20. Thus, the placing of the one or more functional components may be performed after the forming of the first layer 20 to the shape of the mould 10.

[0144] In an embodiment, the mould further comprises one or more accommodating portion features for forming one or more accommodating portions. Accommodating portions may be portions that are configured to accommodate functional components. For example, the accommodating portions may be portions that are configured to accommodate one or more of terminations, fixings and protection. The accommodating portions may be formed in the first layer 20.

[0145] An accommodating portion feature may have a shape which corresponds to the desired shape of an accommodating portion. The accommodating portion features may be recessed into the upper surface 11 of the mould 10, i.e. the accommodating portion features may be recesses. The method may further comprise forming the one or more accommodating portions in the first layer 20. When the first layer 20 is formed to the shape of the mould 10, portions of the first layer 20 may form to the shape of theaccommodating portion features to form the accommodating portions. The step of placing the one or more functional components described above may comprise placing the one or more functional components in the one or more accommodating portions formed in the first layer 20. Where a functional component is configured to be connected to a functional member 34a-d, an accommodating portion may be adjacent to a channel 24a-d (and thus, an accommodating portion feature may be adjacent to a groove 14a-d). Alternatively, where a functional component is configured to be connected to a functional member 34a-d, an accommodating portion may, at least partially, occupy the same space as a channel 24a-d (and, thus, an accommodating portion and a groove 14a-d may be contiguous recesses in the mould 10).

[0146] In an embodiment, the first layer 20 comprises holes (not shown) formed therein. Additionally or alternatively, the second layer 40 comprises holes (not shown) formed therein. The holes in the first layer 20 and / or the holes in the second layer 40 may be configured to facilitate access to the functional components. For example, a hole in the first layer and / or the second layer may allow an external component to be connected to a termination. In some embodiments, the holes in the first layer 20 and / or the second layer 40 allow the functional component to protrude therethrough.

[0147] A specific example of how a functional component may be installed within a product will now be described. In this example, the mould 10 comprises an accommodating portion feature and a groove. When the first layer 20 is formed to the shape of the mould 10, an accommodating portion and a channel 24a-d are formed in the first layer 20 by the accommodating portion feature and the groove 14a-d, respectively. The accommodating portion and the channel 24a-d may be adjacent, or occupy the same space. A functional member 34a-d and a functional component are then placed in the channel 24a-d and the accommodating portion, respectively. The functional member and the functional component may be connected. For example, the functional member may be a wire, and the functional component may be a termination for the wire. The second layer 40 is then placed over the first layer 20, the functional member 34a-d and the functional component. The second layer 40 comprises a hole. The hole aligns with the functional component, such that the functional component can be accessed through the hole in the second layer 40. For example, in the case that the functional member is a wire and the functional component is a termination, an external wire may be connected to the functional component.In an embodiment, the first layer 20 may have a non-uniform thickness.

[0148] Additionally or alternatively, the second layer 40 may have a non-uniform thickness. The product comprises one or more stress regions and one or more non-stress regions. Stress regions may be regions in which the product is likely to experience significant mechanical stresses (i.e. stresses resulting from strain (or deformation) of the product). A significant mechanical stress may be a mechanical stress with a large magnitude or a cyclic mechanical stress. Stress regions may be regions in which the product is likely to experience significant stress from the environment, e.g. from water, or from UV radiation. The method may comprise providing a first layer 20 with a first thickness in areas corresponding to the one or more stress regions and a second thickness in areas corresponding to the one or more non-stress regions. The first thickness may be greater than the second thickness. Additionally or alternatively, the method may comprise providing a second layer 40 with a third thickness in areas corresponding to the one or more stress regions and a fourth thickness in areas corresponding to the one or more non-stress regions. The third thickness may be greater than the fourth thickness.

[0149] In the foregoing description, an embodiment has been described in which the product comprises only two layers, with the functional members enclosed therebetween. However, the product may comprise more than two layers, and functional members may be enclosed between different ones of the more than two layers.

[0150] In an embodiment, the product comprises three layers: a first layer 20, a second layer 40, and a third layer (not shown). As described above, functional members 34a-d are placed between the first layer 20 and the second layer 40. One or more further functional members are interposed between the second layer 40 and the third layer. That is, in combination, the second layer 40 and the third layer may form a sleeve within which further functional members are enclosed. To form such a product, after the step S3 of placing the second layer 40 over the first layer 20 and the plurality of functional members 34a-d, the one or more further functional members may be placed on the second layer 40. Then, the third layer may be placed over the second layer 40 and the one or more further functional members.

[0151] The one or more further functional members may be placed in the grooves 14a-14d in the mould. That is, one or more of the grooves 14a-14d in the mould may be configured for more than one functional member to be placed therein. In an embodiment, a functional member 34a-d is placed in a groove 14a-d. Then, the second layer 40 is placed over the functional member 34a-d. Then a further functional member is placed in the same groove14a-d. Then, the third layer may be placed over the further functional member. In this case, a depth of the groove 14a-14d may be approximately equal to the sum of the thickness of the first layer, the diameter of the functional member placed in the groove first, the thickness of the second layer, and the diameter of the further functional member placed in the groove. This may be particularly useful in embodiments in which the functional members are bare wires, because the layer that is interposed between vertically adjacent functional members (i.e. the second layer 40 in the example provided in this paragraph) may isolate the functional members from one another.

[0152] In embodiments in which the functional member is a coated wire, it may not be necessary to provide a layer between vertically adjacent functional members.

[0153] As will be appreciated, a product may comprise more than three layers. To form a product with more than three layers, the steps of adding one or more functional members and then placing a layer over the newly-added functional members may be repeated as often as is required. If a plurality of functional members are to be placed on top of each other in a single groove, a depth of the groove may be approximately equal to the sum of the diameters of the plurality of functional members and the thicknesses of the layers between the plurality of functional members.

[0154] In an embodiment, two or more products may be manufactured simultaneously. That is, two or more products may be manufactured during a single repetition of the method.

[0155] In an embodiment, part or all of the method is automated.

[0156] The method described above may be performed by a system. The system may comprise the various components described above and a controller. The controller may comprise a computer program comprising instructions, which, when executed, cause the controller to control the system to perform the method described in the present application. The controller may comprise a computer-readable medium on which the computer program is stored. The controller may be referred to as a computer.

[0157] Aspects of the invention are described in the following numbered clauses.

[0158] 1. A method of manufacturing a product, the method comprising:

[0159] forming a first layer to a shape of a mould, wherein the mould defines one or more grooves;

[0160] placing one or more functional members in the one or more grooves; andplacing a second layer over the first layer and the one or more functional members, such that the one or more functional members are enclosed within a sleeve formed by the first layer and the second layer.

[0161] 2. The method according to claim 1, wherein the one or more functional members comprise at least one of

[0162] (i) one or more conductive members, optionally wherein the conductive members are wires, and further optionally wherein the wires are coated or bare;

[0163] (ii) one or more fibre optic members, optionally wherein the fibre optic members are fibre optic cables;

[0164] (iii) one or more structural members, optionally wherein the structural members are ropes, strings, structural fibres or structural filaments; and

[0165] (iv) one or more pneumatic lines, one or more or hydraulic lines, one or more vacuum lines, or one or more flexible pipes.

[0166] 3. The method according to claim 1 or 2, wherein:

[0167] when the first layer is formed to the shape of the mould, portions of the first layer form to the one or more grooves to form one or more channels; and

[0168] the placing one or more functional members in the one or more grooves comprises placing the one or more functional members in the one or more channels.

[0169] 4. The method according to any of the preceding claims, wherein the placing the second layer over the first layer and the one or more functional members comprises pulling the second layer onto the first layer or pushing the second layer onto the first layer.

[0170] 5. The method according to any of the preceding claims, wherein the forming the first layer to the shape of the mould comprises vacuum moulding.

[0171] 6. The method according to claim 5, wherein the vacuum moulding comprises exerting a first pulling force on the first layer with a vacuum arrangement, and the pulling the second layer onto the first layer comprises applying a second pulling force on the second layer using the vacuum arrangement.

[0172] 7. The method according to any of the preceding claims, wherein the placing the second layer over the first layer and the one or more functional members comprises vacuum lamination.

[0173] 8. The method according to any of the preceding claims, further comprising bonding the second layer to the first layer.

[0174] 9. The method according to claim 8, wherein the bonding the second layer to the first layer comprises thermal bonding, use of an adhesive, or use of a thermoplastic polymer.10. The method according the any of the preceding claims, further comprising, after the placing the second layer over the first layer and the one or more functional members, removing first regions of the first layer and the second layer.

[0175] 11. The method according to claim 10, wherein one or more second regions of the first layer and the second layer surround the one or more functional members, and the removing the first regions of the first and the second layer is performed such that the second regions remain.

[0176] 12. The method according to claims 10 or 11, wherein the removing the first regions of the first layer and the second layer comprises laser texturing or mechanical cutting.

[0177] 13. The method according to any of the preceding claims, wherein the placing the one or more functional members in the one or more grooves is performed using a robotic tool.

[0178] 14. The method according to claim 13, wherein the placing the one or more functional members in the one or more grooves comprises simultaneously placing a plurality of functional members in a plurality of grooves using the robotic tool.

[0179] 15. The method according to claim 14, wherein the robotic tool comprises a feed head with a plurality of feed outputs for simultaneously placing the plurality of functional members in the plurality of grooves, wherein the plurality of feed outputs are optionally arranged in a direction that is substantially perpendicular to a direction of travel of the feed head.

[0180] 16. The method according to claim 15, wherein feed rates of the plurality of feed outputs are independently controllable.

[0181] 17. The method according to claim 16, wherein the feed rates of the plurality of feed outputs can be changed independently.

[0182] 18. The method according to claim 16 or 17, further comprising changing the feed rates through each of the feed outputs as a function of time to ensure that lengths of the plurality of functional members output from the feed outputs is approximately equal to lengths of the plurality of channels.

[0183] 19. The method according to any of the preceding claims, wherein the one or more grooves are formed on a substantially flat, planar surface of the mould.

[0184] 20. The method according to any of claims 1 to 18, wherein the one or more grooves are formed on a non-planar surface of the mould, and the profile of the non-planar surface corresponds to a target profile for the product.21. The method according to any of the preceding claims, wherein a width of a groove is such that an interference fit is formed between the groove and a functional member that is placed into the groove.

[0185] 22. The method according to any of the preceding claims, wherein the first layer is bonded to the second layer at an interface which locally defines an interface plane, and the method is performed such that the functional members are located on one side of the interface plane.

[0186] 23. The method according to claim 22, wherein a depth of a groove is approximately equal to the sum of a diameter of a functional member that is placed in the groove and a thickness of the first layer.

[0187] 24. The method according to any of claims 1 to 21, wherein the first layer is bonded to the second layer at an interface which locally defines an interface plane, and the method is performed such that the one or more functional members extend across the interface plane.

[0188] 25. The method according to claim 24, wherein the method is performed such that a plane bisecting a cross-section of the one or more functional members is approximately coplanar with the interface plane.

[0189] 26. The method according to claims 24 or 25, wherein a depth of a groove is approximately equal to the sum of half the diameter of a functional member that is placed in the groove and a thickness of the first layer.

[0190] 27. The method according to any of the preceding claims, further comprising providing an insulative layer and / or a shielding layer to the first layer before and / or after the placing the one or more functional members in the grooves.

[0191] 28. The method according to any of the preceding claims, further comprising bonding the one or more functional members to the first layer.

[0192] 29. The method according to any of the preceding claims, wherein:

[0193] the mould comprises one or more bend portion features for forming one or more bend portions in the first layer and the second layer;

[0194] the bend portions are configured to facilitate bending at the bend portions; and

[0195] the method further comprises forming the one or more bend portions.

[0196] 30. The method according to any of the preceding claims, further comprising: removing the product from the mould; and

[0197] bending the product.

[0198] 31. The method according to claim 30, wherein:the mould comprises one or more bend portion features for forming one or more bend portions in the first layer and the second layer;

[0199] the bend portions are configured to facilitate bending at the bend portions;

[0200] the method further comprises forming the one or more bend portions; and

[0201] the bending the product is performed at the one or more bend portions.

[0202] 32. The method according to any of the preceding claims, further comprising, after the step of forming the first layer to the shape of the mould, placing one or more of terminations, fixings and protection on the first layer.

[0203] 33. The method according to any of the preceding claims, wherein the mould comprises one or more accommodating portion features for forming one or more accommodating portions, and the method further comprises forming the one or more accommodating portions in the first layer, optionally wherein the one or more accommodating portions are configured to accommodate one or more of terminations, fixings and protection.

[0204] 34. The method according to claim 33, wherein the accommodating portion features are recesses in the mould.

[0205] 35. The method according to claim 33 or 34, wherein the one or more of the terminations, fixings and protection are placed in the accommodating portions.

[0206] 36. The method according to any of claims 32 to 35, wherein the first layer and / or the second layer comprise one or more holes formed therein, and the one or more holes are configured to facilitate access to the one or more of terminations, fixing and protection. 37. The method according to any of the preceding claims, further comprising heating the mould before and / or during the forming the first layer to the shape of the mould.

[0207] 38. The method according to any of the preceding claims, further comprising heating the functional members before and / or during the placing the one or more functional members in the one or more grooves.

[0208] 39. The method according to any of the preceding claims, further comprising heating the first layer before forming the first layer to the shape of the mould.

[0209] 40. The method according to any of the preceding claims, wherein the first layer and / or the second layer has a non-uniform thickness.

[0210] 41. The method according to claim 40, wherein the product comprises one or more stress regions and one or more non-stress regions, and the method further comprises at least one of:(i) providing a first layer with a first thickness in areas corresponding to the one or more stress regions and a second thickness in areas corresponding to the one or more non-stress regions, wherein the first thickness is greater than the second thickness; and

[0211] (ii) providing a second layer with a third thickness in areas corresponding to the one or more stress regions and a fourth thickness in areas corresponding to the one or more nonstress regions, wherein the third thickness is greater than the fourth thickness.

[0212] 42. The method according to any of the preceding claims, further comprising forming the mould using an additive manufacturing technique.

[0213] 43. The method according to any of the preceding claims, wherein at least one of the first layer and the second layer is a film, and optionally wherein the film is formed of a material comprises a polymer.

[0214] 44. The method according any of the preceding claims, further comprising placing one or more further functional members on the second layer, and placing a third layer over the second layer and the one or more further functional members.

[0215] 45. The method according to claim 44, wherein the one or more further functional members are placed in the one or more grooves.

[0216] 46. The method according to claim 45, wherein a depth of a groove is approximately equal to the sum of the thickness of the first layer, a diameter of a functional member placed in the groove, a thickness of the second layer, and a diameter of a further functional member placed in the groove.

[0217] 47. A method of manufacturing two or more products during a single repetition of the method according to any of the preceding claims.

[0218] 48. The method according to any of the preceding claims, wherein the method is automated.

[0219] 49. The method according to any of the preceding claims, wherein the product is a wiring harness.

[0220] 50. A product obtained using the method according to any of the preceding claims. 51. A computer program comprising instructions which, when executed, cause a computer to control a system to perform the method of any of claims 1 to 49.

[0221] 52. A computer-readable medium storing the computer program of claim 51.

[0222] 53. A system configured to perform the method according to any of claims 1 to 49.

Claims

CLAIMS1. A method of manufacturing a product, the method comprising: forming a first layer to a shape of a mould, wherein the mould defines one or more grooves;placing one or more functional members in the one or more grooves; and placing a second layer over the first layer and the one or more functional members, such that the one or more functional members are enclosed within a sleeve formed by the first layer and the second layer.

2. The method according to claim 1, wherein the one or more functional members comprise at least one of:(i) one or more conductive members, optionally wherein the conductive members are wires, and further optionally wherein the wires are coated or bare;(ii) one or more fibre optic members, optionally wherein the fibre optic members are fibre optic cables;(iii) one or more structural members, optionally wherein the structural members are ropes, strings, structural fibres or structural filaments; and(iv) one or more pneumatic lines, one or more or hydraulic lines, one or more vacuum lines, or one or more flexible pipes.

3. The method according to claim 1 or 2, wherein:when the first layer is formed to the shape of the mould, portions of the first layer form to the one or more grooves to form one or more channels; andthe placing one or more functional members in the one or more grooves comprises placing the one or more functional members in the one or more channels.

4. The method according to any of the preceding claims, wherein the placing the second layer over the first layer and the one or more functional members comprises pulling the second layer onto the first layer or pushing the second layer onto the first layer.

5. The method according to any of the preceding claims, wherein the forming the first layer to the shape of the mould comprises vacuum moulding,optionally wherein the vacuum moulding comprises exerting a first pulling force on the first layer with a vacuum arrangement, and the pulling the second layer onto the first layer comprises applying a second pulling force on the second layer using the vacuum arrangement.

6. The method according to any of the preceding claims, wherein the placing the second layer over the first layer and the one or more functionalmembers comprises vacuum lamination.

7. The method according to any of the preceding claims, further comprising bonding the second layer to the first layer,optionally wherein the bonding the second layer to the first layer comprises thermal bonding, use of an adhesive, or use of a thermoplastic polymer.

8. The method according the any of the preceding claims, further comprising, after the placing the second layer over the first layer and the one or more functional members, removing first regions of the first layer and the second layer,optionally wherein one or more second regions of the first layer and the second layer surround the one or more functional members, and the removing the first regions of the first and the second layer is performed such that the second regions remain,optionally wherein the removing the first regions of the first layer and the second layer comprises laser texturing or mechanical cutting.

9. The method according to any of the preceding claims, wherein the placing the one or more functional members in the one or more grooves isperformed using a robotic tool,optionally wherein the placing the one or more functional members in the one or more grooves comprises simultaneously placing a plurality of functional members in a plurality of grooves using the robotic tool,further optionally wherein the robotic tool comprises a feed head with a plurality of feed outputs for simultaneously placing the plurality of functional members in the plurality of grooves, wherein the plurality of feed outputs are optionally arranged in a direction that is substantially perpendicular to a direction of travel of the feed head,further optionally wherein feed rates of the plurality of feed outputs are independently controllable,further optionally wherein the feed rates of the plurality of feed outputs can be changed independently.further optionally wherein the method further comprising changing the feed rates through each of the feed outputs as a function of time to ensure that lengths of the plurality of functional members output from the feed outputs is approximately equal to lengths of the plurality of channels.

10. The method according to any of the preceding claims, wherein a width of a groove is such that an interference fit is formed between the groove and a functional member that is placed into the groove.

11. The method according to any of the preceding claims, wherein the first layer is bonded to the second layer at an interface which locally defines an interface plane, and the method is performed such that the functional members are located on one side of the interface plane,optionally wherein a depth of a groove is approximately equal to the sum of a diameter of a functional member that is placed in the groove and a thickness of the first layer.

12. The method according to any of claims 1 to 10, wherein the first layer is bonded to the second layer at an interface which locally defines an interface plane, and the method is performed such that the one or more functional members extend across the interface plane,optionally wherein the method is performed such that a plane bisecting a crosssection of the one or more functional members is approximately co-planar with the interface plane,further optionally wherein a depth of a groove is approximately equal to the sum of half the diameter of a functional member that is placed in the groove and a thickness of the first layer.

13. The method according to any of the preceding claims, further comprising bonding the one or more functional members to the first layer.

14. The method according to any of the preceding claims, wherein: the mould comprises one or more bend portion features for forming one or more bend portions in the first layer and the second layer;the bend portions are configured to facilitate bending at the bend portions; andthe method further comprises forming the one or more bend portions.

15. The method according to any of the preceding claims, further comprising:removing the product from the mould; andbending the product,optionally wherein:the mould comprises one or more bend portion features for forming one or more bend portions in the first layer and the second layer;the bend portions are configured to facilitate bending at the bend portions; the method further comprises forming the one or more bend portions; and the bending the product is performed at the one or more bend portions.

16. The method according to any of the preceding claims, wherein the mould comprises one or more accommodating portion features for forming one or more accommodating portions, and the method further comprises forming the one or more accommodating portions in the first layer, optionally wherein the one or more accommodating portions are configured to accommodate one or more of terminations, fixings and protection,optionally wherein the accommodating portion features are recesses in the mould, optionally wherein the one or more of the terminations, fixings and protection are placed in the accommodating portions,optionally wherein the first layer and / or the second layer comprise one or more holes formed therein, and the one or more holes are configured to facilitate access to the one or more of terminations, fixing and protection.

17. The method according to any of the preceding claims, further comprising heating the mould before and / or during the forming the first layer to the shape of the mould.

18. The method according to any of the preceding claims, further comprising heating the functional members before and / or during the placing the one or more functional members in the one or more grooves, and / or heating the first layer before forming the first layer to the shape of the mould.

19. The method according to any of the preceding claims, wherein the first layer and / or the second layer has a non-uniform thickness,optionally wherein the product comprises one or more stress regions and one or more non-stress regions, and the method further comprises at least one of:(i) providing a first layer with a first thickness in areas corresponding to the one or more stress regions and a second thickness in areas corresponding to the one or more nonstress regions, wherein the first thickness is greater than the second thickness; and(ii) providing a second layer with a third thickness in areas corresponding to the one or more stress regions and a fourth thickness in areas corresponding to the one or more non-stress regions, wherein the third thickness is greater than the fourth thickness.

20. The method according to any of the preceding claims, further comprising forming the mould using an additive manufacturing technique.

21. The method according any of the preceding claims, further comprising placing one or more further functional members on the second layer, and placing a third layer over the second layer and the one or more further functional members, optionally wherein the one or more further functional members are placed in the one or more grooves,further optionally wherein a depth of a groove is approximately equal to the sum of the thickness of the first layer, a diameter of a functional member placed in the groove, a thickness of the second layer, and a diameter of a further functional member placed in the groove.

22. A product obtained using the method according to any of the preceding claims.

23. A computer program comprising instructions which, when executed, cause a computer to control a system to perform the method of any of claims 1 to 21.

24. A computer-readable medium storing the computer program of claim 23.

25. A system configured to perform the method according to any of 5 claims I to 21.

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