Recently, samples of a PVC modular window were produced for a major North American OEM. This modular window included a roll formed swept metal division bar which was encapsulated along with a curved piece of tempered glass and one metal attachment stud. Initial samples met all criteria for dimensional, functional and cosmetic requirements. The success of the program can be attributed to analytical and experimental development work accomplished early in the program.This paper will review how results of analytical mold fill simulations, finite element analysis and experimental adhesion development were integrated into this product. Also, the key design criteria, tooling concepts, and process parameters will be discussed.