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The Objective of this paper is to explain a procedure for using Arbitrary Shape Deformation (ASD) technology coupled with Computational Fluid Dynamics (CFD) software for product development of a generic catalytic converter inlet-cone diffuser. The paper uses the development of an inlet-cone diffuser as an example of such a process. The non-uniformities of the flow field at the inlet of the catalytic converter bricks are considered to have a negative impact on the converter performance. Computational Fluid Dynamics (CFD) is a powerful tool for computing the flow field in the exhaust system and the catalytic converter which enables the engineers to optimize the geometry of the inlet cone at a very early design stage. The goal of this study is to optimize the shape of an inlet-cone diffuser upstream of a catalytic converter to reduce the pressure drop and maximize the uniformity of exhaust gas distribution on the catalytic converter inlet.