Abstract: This paper reported a reverse engineering modeling method as well as amold design for the handle back cover of a hair dryer. A multiple scan was firstly carried out for this plastic back cover using a scanner to obtain point cloud, and then the geometric model was reconstructed. The design schemes of mold cooling and pouring systems were analyzed by using the Moldflow software to gain the optimal design proposal. A suitable formwork was selected, and the structure of the outlet was also designed. The overall structure of the mold wasdesigned successfully. The whole design process in this workcan provide useful guidance for the design of similar molds with complicated structures.