The automotive lighting industry continues to optimize the balance between heat performance and cost performance for exterior lighting components. Headlamp bezel applications, in particular, must meet stringent heat and aesthetic requirements while delivering a part that meets cost and mass needs. This drive is inspiring the development of next generation, enhanced flow, high heat materials as well as the need for accurate processing prediction. Process simulation is one of the best tools to be leveraged at the design phase for evaluating optimization opportunities. The objective of this paper is to present the novel methodology of design simulation and experimental validation with six sigma concepts.