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With the adoption of complex technologies such as multiple injections, EGR and variable geometry turbocharging, it has become increasingly onerous to develop optimal engine control calibrations for either light- or heavy-duty diesel engines. The addition of NOx and PM aftertreatment systems increases further the calibration burden, as both diesel particulate filters and NOx absorbers require regeneration initiated by the engine management system. There is significant interest in the industry in reducing development costs by moving as much of the engine calibration process as is feasible from the engine test cell to the virtual desktop environment. This paper describes the development of a model-based calibration optimization system that offers significant advantages in reducing the time and effort required to obtain certification-quality engine calibrations.