In an investigation to gain a deeper understanding of the relationship between port geometry and performance characteristics, a parametic intake port design tool has been developed using statistical design-of-experiment (DOE) techniques. Flow coefficient is a very important parameter, constraints are used to represent additional features in the external packaging requirements. A thorough assessment of performance was made possible by using rapid-prototype models and numerical simulation and the intake port steady flow. The in-cylinder flows were successfully validated by comparing predicted results with new test data. By analyzing the DoE data a design method was developed and used to predict optimum design configurations for a range of common diesel engine applications.