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This research focuses on utilizing injection moulding to assess defects in plastic products, including sink marks, shrinkage, and warpages. Process parameters, such as pure cooling time, mould temperature, melt temperature, and pressure holding time, are carefully selected for investigation. A full factorial design of experiments is employed to identify optimal settings. These parameters significantly affect the physical and mechanical properties of the final product. Soft computing methods, such as finite element (FE), help mitigate behaviour by considering different input parameters. A CAD model of a dashboard component integrates into an FE simulation to quantify shrinkage, warpage, and sink marks. Four chosen parameters of the injection moulding machine undergo comprehensive experimental design. Decision tree, multilayer perceptron, long short-term memory, and gated recurrent units models are explored for injection moulding process modelling. The best model estimates defects. Multiple objectives particle swarm optimisation extracts optimal process parameters. The proposed method is implemented in MATLAB, providing 18 optimal solutions based on the extracted Pareto-Front., (© 2024. The Author(s).)