This study analyzed and evaluated important parameters in fabrication of Fresnel lens solar collector (melt temperature, mold temperature, packing pressure, and injection speed) based on its two qualities (ratio of power efficiency and percentage error of groove filling ratio). To design the experiment effectively. Taguchi method was applied. The experimental results were analyzed by analysis of variance (ANOVA) in order to derive the significant parameters affecting each quality. Relationships among significant parameters and each quality were established using the response surface methodology (RSM). Two equations were integrated to derive a fitness function, which was optimized by two popular optimization methods - particle swarm optimization (PSO) and genetic algorithm (GA). Optimization results from both methods were chosen based on the highest fitness value. The results showed that with the optimal combination (270 degrees C, 100 degrees C. 1040.4 bar, and 60 mm/s for melt temperature, mold temperature, packing pressure, and injection speed, respectively), a high ratio of conversion efficiency and a low percentage error of groove filling ratio could be successfully derived. Confirmation experiment was conducted to validate the results. (C) 2011 Elsevier Ltd. All rights reserved.