The parabolic leaf spring plays a vital role in suspension systems, since it has an effect on ride comfort and vehicle dynamics. Primarily, leaf spring endurance must be ensured. Presently, there are two approaches to designing a leaf spring.In the traditional method, fatigue tests should be repeated for each case, considering different material, geometry and suspension hard points. However, it takes a long time and requires a heavy budget to get the optimized solution.In the contemporary method, a numerical approach is used to obtain the fatigue life and the leaf geometry against the environmental condition on the basis of material properties.This paper presents a more precise method based on non-linear finite element solutions by evaluating the effects of the production parameters, the geometrical tolerances and the variations in the characteristics of the material. In other words, it is a hybrid method, a blend of the traditional and the recent ones, which correlates the real life conditions and the results of computer aided engineering. Leaf springs of different characteristics were produced and tested in the plant of OlgunCelik plant.The design methodology of this paper also offers a practical approach to industry professionals. The aim was to create a design tool with 2D FEA which is well correlated with 3D.The correlation of 3D and simple 2D methods with experiments are validated through a design of experiment (DOE) study.