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Characteristics of gas penetration and polymer melt flow in gas‐assisted injection molded spiral tubes was investigated by simulations and experiments. Distribution of the skin melt thickness along the gas flow direction was measured, and gas penetration in the primary and secondary stages was identified. An algorithm based on the control‐volume/tiniteelement method combined with a particle‐tracing scheme using a dual‐filling‐parameter technique is utilized to predict the advancements of both melt front and gas from during the molding process. The simulated distribution of gas penetration shows reasonably good coincidence with experimental observations. © 1995 John Wiley & Sons, Inc.

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