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For side airbag, the pipe type inflators have been wide used while the disk type inflators have been used for front airbag. For helping to prevent injury and death the airbag inflator system should be design with great care. The present study deal with optimizing the design of side airbag inflator by finite element analysis and design of experiment method. An optimization process was integrated to determine the optimum design variable values related to the side airbag inflator. Free shape optimization method has been carried out to find a optimal shape on an side airbag inflator model. Optimization of the air bag inflator was successfully developed using Sharpe optimization was carried out to find a new geometry. The improved results compared to the base design specification were achieved from design of experiment and optimization