Injection molding of liquid silicone rubbers (LSR) is widely utilized in the production and insulation of many medium- and high-voltage electrical components. It is dictated mainly by the excellent properties of LSR, ensuring high quality of the final product. However, this also requires a well-established and controlled manufacturing process. Typically, experimental methods are used to get a detailed knowledge regarding the process and to gain the necessary experience. Unfortunately, such an approach is expensive and time consuming, and minimal marketing time is one of the most important requirements for being competitive. In this connection, an advanced silicone molding simulation tool was successfully developed and validated experimentally. Furthermore, computer simulations were applied to analyze and optimize the process for a selected product, avoiding trial and error methods with the only cost connected to the computational time. An accurate representation of the process required a mathematical approach, among others, consisting of viscosity, pVT, and curing kinetics models that were built up based on rheological, pressure, and calorimetric measurements conducted for a considered silicone material. (c) 2012 Wiley Periodicals, Inc. Adv Polym Techn 32: E258E273, 2013; View this article online at wileyonlinelibrary.com. DOI 10.1002/adv.21272