Abstract: Eccentric penetration, inadequate empty, and surface defects were found in a car door handle produced by a gas-assisted injection mold during the tooling test. CAE technology was adopted to discover the causes of these problems. The adjustment of gate location, gas injection location and overflow port location were adjusted, which could effectively eliminate the eccentric gas penetration and surface defect. CAE technology was also used to optimize the processing parameters including the shot size of the melt, gas pressure, gasinjection delay time, mold temperature and melt temperature. As a result, a good gas penetration was achieved. This study confirmed that the CAE technology was a necessary means that can ensure a reasonable design for the gasassisted injection mold as well as optimizes the processing parameters.

Key words: gas-assisted injection molding, car door handle, mould, technological parameter, improvement