The continued advancements in both, the computing power and nonlinear finite element analysis (FEA) are expanding the role of FEA engineers from stress analyst to an object driven design engineer. The resulting end products not only have superior performance but also are cost effective. The integration of nonlinear FEA with design optimization allows complex geometries to be studied under a variety of conditions leading to an optimized part design. Carefully established design rules and objectives with a focus on manufacturability of parts in production environment can lead to a feasible and profitable design.Designs using elastomeric materials have been developed in the past on the basis of experience and trial-error processes. A more scientific and fundamental approach can be taken by using nonlinear FEA to study the effect of various design parameters on a design. The development of a Canned Polyurethane Wiper has been discussed in this paper with special emphasis on deformation and stress patterns.