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Nowadays, plasticization on vehicle becomes one of the three most popular research directions in the automotive field worldwide. Plastic has many good features for example: light weight, rich series, cheap, can form free shapes, good insulation, shock resistance, good flexibility, chemical resistance, molding easily, recyclable, etc, thus, they are widely used on manufacturing automotive parts, especially on autobody (interiors, body accessories). Besides, with the three times petroleum crisis and nearly exhausted petroleum resources, the demands for lighter and more energy saving vehicles are increasing, so the plasticization on automotive parts is quickly developed. During the progress of plasticization on automotive parts, the plasticization on automotive lighting system is especially quickly developed, in less than 10 years, the main parts (for example lamp body, reflector, mask and so on), have all been plasticized. In the mean time, the lighting products not only have innovative shapes, good structures, but also use fine materials, high accurate level, good quality on surface, and so on, which make the lighting parts most accurate plastic parts on vehicle. New lamps bring higher demands for products designer and products manufacturer, then there comes the dropping behind of the traditional design ways and methods on plastics parts. So, the application of CAD technology can obviously shorten the products’design time, improve the quality level of products and the accurate level of molds, consequently increase the success ratio of testing molds at first time. Modern lamp’s structures become more and more complicated, it contains many parts, especially the headlamp’s mask, its materials should have good abilities like shock resistance, good transparency and heat resistance. Therefore, the PC is used for manufacture, as well as, PC has small molding shrinkage ratio, stabilization on dimensions, high fusion ratio, good sensitivity on temperature and stable sensitivity on pressure. Thus, the choice of headlamp’s mask in this thesis is not only very representative, but also can be spread to other parts’progress of design and manufacture. This thesis began at March of 2004, it undergoes periods of theory studying, reading technical thesis and materials, internship in the plants, learning software Moldflow, focus on the flow and cool simulation on the “Audi C6”headlamp’s mask and later the analyst on the results. This thesis analyses the simulation results in detail, and studies the problems possibly happened on the plastic parts, for example air traps, welding lines, filling time and pressure etc., accordingly, the solving ways
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