Process simulations in micro injection moulding aim at the optimization and support of the design of the mould, mould inserts, the plastic product, and the process. Nevertheless, dedicated software packages for micro injection moulding are not available. They are developed for macro plastic parts and are therefore limited in the capability of modelling the polymer flow in micro cavities. Hence, new strategies for comprehensive simulation models which provide more precise results open up new opportunities and will be discussed. Modelling and meshing recommendations are presented, leading to a multi-scale mesh of all relevant units of the injection moulding system. The implementation of boundary conditions, e.g. machine and venting, and results illustrating their importance on the simulation accuracy are presented.