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Recently the automotive industry has focused on reducing product development time to correspond with the customer's demands. Especially when quickly changed. The decreased product development time shortens the quality assurance period. It makes difficult to guarantee the quality of the products. The improved quality assurance is required so that customer's expectations are actually higher quality than in the past. Most automotive interior parts are manufactured by using plastic. It is very sensitive to focus on quality, because it is exposed to a passenger's sight. So automotive interior companies make full use of injection molding CAE in an effective ways to reduce costs and reduce elements of poor quality. This paper suggests a methodology that improves reliability for injection molding analysis in grille shapes of door trim. And it involves an experimental analysis of flow pattern in speaker grille shapes.

Recently, major car maker is specified squeak and rattle test method for subsystems or components by objective method. Generally these test method is focused on vibration environmental conditions. Especially, door trim which is located close to occupant is required additional test for squeak and rattle which is produced by occupant's interaction with door trim. To evaluate this condition, generally it can be tested by subjective method such as striking or pushing and twisting several positions of door trim. Dosing so is very time consuming and including variation results as different decisions. So, this paper suggest a new approach for evaluating squeak and rattle which is relating occupant contacting conditions to interior part, especially interior door trim. Multi-axis robot arm is examined to push automatically several points of door trim.

The complete evaluation of the side vehicle structure and occupant protection is only possible by the full-scale side impact crash test. But auto part manufactures, such as door trim makers can't conduct the test especially when the vehicle is under developing process. And important information and components for estimating crash performance is restricted. With the proposed design procedure for the door trim by a simple impact test method was demonstrated to evaluate the abdominal injury. In addition to simple test, Euro-NCAP test result that is conducted by referenced full-scale test in Korea is compared with several test results. In conclusion, this simple test method have similar trend for abdominal injury index so that it is possible to present guidelines of door armrest design to carmaker at the early stages of vehicle program development.