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Structural integrity is a characteristic that must be evaluated during development of plastic parts as door trim panels. One of the critical areas in door trims is the interface between different parts that often use heat stakes due to process capacity and low costs. To predict issue on those interfaces, a methodology combining finite element analysis (FEA) and physical test results was applied to drive design in two door trim designs, with different material combinations. Aiming to support FEA conclusions, physical tests were performed to determine the maximum retention force that a heat stake withstands, indicating values about 168N for heat stakes of medium impact polypropylene blend >PP+EP(D)M-T<. and 216N for stakes of unfilled polypropylene copolymer >PP<. These values were used as upper limits for reaction forces provided by FEA in each heat stake under a load of 600 N at Pull Handle.