Recently, the application range of plastic gears is widely expanding by the development of engineering plastics with good mechanical properties. Plastic gears have excellent performances such as light weight, water resistance and vibration absorbing ability for metallic gears. In this study, the optimization of injection molding process was done for the large disk type plastic gears of auto phoropter. Design Of Experiment (Taguchi method) was adopted to find a tendency of molding conditions that influence the flatness of disk type gear. Four main factors for molding conditions were selected based on injection temperature, filling time, packing pressure and mold temperature. Also, Filling, packing and cooling analyses were carried out to evaluate Z directional deflection of large disk type gear by using the simulation software (Moldflow) based on the DOE. From the results, it was found that the injection temperature and packing pressure are the most sensitive parameters for the Z directional deflection of large disk type gears.