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Seamless Passenger Airbag Door, which means the seam of the passenger airbag door is not visible to the passenger, is being frequently implemented in the instrument panel because of its good surface appearance. But it is always a challenge to design a robust passenger airbag door with an invisible seam because many kinds of failures are possible during the design, such as cracks of the substrate of instrument panel, hinge failure of airbag door, windshield breakage, etc. Besides the engineering difficulties, the simulation of seamless passenger airbag door deployment is challenging due to three aspects: 1. the simulation method of the early stage airbag deployment (0~20 msec after trigger), 2. the material model of the airbag door pre-weakening line (the invisible seam); and 3. the physical measurement of the reaction load between cushion and door.