Abstract: A method of predicting optimal injection molding cycle time includes the steps of performing a thermal analysis through a thickness of a part made using an injection mold, calculating shrinkage as a function of cooling time, calculating friction forces between the part and mold, calculating ejection forces based on the coefficient of friction and the calculated shrinkage calculating the induced stress in selected high stress areas on the part, and comparing the induced stress with material yield stress to determine an optimal cycle time window within which the part can be ejected without being damaged.