The hybrid natural shape optimal design approach is used along with a nonlinear programming (NLP) technique to find the optimal shapes of electronic packaging components. The design problems are formulated as min-max problems, and linear and materially nonlinear finite element analyses provide the function values. The applicability of the developed methodology is illustrated using a design example that deals with the packaging design of a plastic pad array carrier digital package. The results indicate that the methodology can be used as an effective way of evaluating different design alternatives or as a way of refining existing designs. The methodology and the tool set considered here have the potential to reduce the design cycle time in new product development efforts.