During many forming processes, gaps open and close along the interface between the cooling part and the tool or mould. The influence of the gaps on the rate of heat transfer between the cooling part and the mould may be significant. In these cases, it is necessary to use a fully coupled analysis approach in modelling the process due to the two-way coupling between temperature and displacement. This phenomenon is investigated for the case of the overinjection process. Coupled finite element modelling of each step of the manufacturing process is performed. Results show very close agreement with temperature measurements and process induced deformations of the finished part. (c) 2006 Elsevier B.V. All rights reserved.