A novel design technique that is used to optimize contact pressure distribution was introduced and investigated. The primary objective of this design tool, called the Predicted Displacement Method, was to provide a calculated contact surface shape alteration of a contact body that induces a uniform contact pressure across its entire nominal contact surface when pressed against its destination contact boundary at a specified magnitude. This technique was developed so it could be applied to any contact surface to spread out a once poorly distributed and localized contact pressure distribution. The methodology was detailed in this work and a proof of concept was conducted to test the idea's feasibility. The proof of concept supported the methodology's ability to shape a cantilevered beam so that it pressed against a semi-infinite space uniformly. This methodology was then applied to two relevant contact assemblies and resulted in uniform contact across each contact interface. The results also illustrated the ability to control contact magnitude and demonstrated improved contact distribution at magnitudes beyond the design value. The methodology presented in this work provides engineers with a analytical and numerical tool to improve contact pressure distribution between any contact surfaces. Possible future use of this methodology includes incorporation into engineering software packages for contact surface design.

Master of Science