Optimal design of an automotive catalytic converter for minimization of cold-start emissions is numerically performed using a micro genetic algorithm for two optimization problems: optimal geometry design of the monolith for various operating conditions and optimal axial catalyst distribution. The optimal design process considered in this study consists of three modules: analysis, optimization, and control. The analysis module is used to evaluate the objective functions with a one-dimensional single channel model and the Romberg integration method. It obtains new design variables from the control module, produces the CO cumulative emissions and the integral value of a catalyst distribution function over the monolith volume, and provides objective function values to the control module. The optimal design variables for minimizing the objective functions are determined by the optimization module using a micro genetic algorithm. The control module manages the optimal design process that mainly takes place in both the analysis and optimization modules.