Abstract: The finite element method is adopted to simulate the film posting process of outside mold decoration (OMD) by using polycarbonate (PC) as a film material. The distribution of the film thickness and the film deformation contours in x and y directions were derived from this simulation, and the influence factors of film molding were analyzed. In order to achieve a minimum standard deviation in average film thickness and x and ydirectional deformation, an optimal latin hypercube sampling method was adopted to establish the approximate model, and the process parameters of film molding was analyzed by a global optimization model. The results indicated that the uniform distribution of film thickness and high deformation accuracy were achieved on the basis of such a global optimization model.

Key words: out-side mold decoration, simulation, global optimization