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Computational Analysis and Engineering using P-Cat, WAVE, HeatCad, Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) are sequentially applied to design, develop, and optimize catalytic converter. P-Cat is used to estimate back pressure due to substrates, end cones, and inlet/outlet pipes. WAVE simulation is used to predict the exhaust system back pressure from the engine headface to tail pipe to estimate engine performance. Heatcad, a transient heat transfer analysis is used to simulate the temperature response in the exhaust system to locate the catalytic converter to achieve maximum performance. Heatcad analysis provides the easy way to identify thermal management issues and to design and optimize the runner lengths, material thicknesses of the manifold and downpipes.