Ionizing radiation is increasingly used as an alternative to post‐harvest crop fumigation by methyl bromide. We studied the effects of gamma irradiation on Helicoverpa assulta (Lepidoptera: Noctuidae) at different stages of development to determine the minimal dose for the prevention of normal emergence of adults. We selected five doses of gamma rays (100, 200, 300, 400 and 500 Gy) based on preliminary experiments and irradiated eggs, larvae, pupae and adults. A dose of 100 Gy to eggs allowed 21.83% of larvae to pupate, but these all died during the pupal stage. A dose of 100 Gy to last‐instar larvae caused larval or pupal death, or the emergence of abnormal adults; no normal adults developed. Irradiation of pupae with doses of 300 Gy and above resulted either in their death or emergence of abnormal adults; however, after 100 or 200 Gy, normal adults emerged and F1 eggs were produced, but no eggs hatched. Following irradiation of adults, eggs were produced at all doses, although the numbers were significantly decreased compared to untreated controls (P < 0.05; 69.45–125.50 vs. 475.05 eggs per female); however, none of the eggs hatched. As prevention of normal emergence is a key outcome for measuring the effectiveness of radiation, then the 100 Gy dose was effective for irradiation of eggs and larvae, and 300 Gy for pupae.