A virtual prototyping environment for a robust design of an injection moulding process.

•A new approach able to optimise the injection moulding is proposed and detailed to an industrial case.•FEM, RSM and stochastic simulations are combined in a virtual prototyping environment.•A proposed procedure permits to compare FEM prediction with measurements in the production.•The optimisation of process parameters is performed numerically on a virtual model.•It is robust taking in account stochastic fluctuations of parameters with a minimum of computation.