Finite element analysis is performed to evaluate stress and deformation of a wrinkle-type dust cover for the ball joints of tie rods of automotive steering system. Results of the analysis for assembly and operation condition show that sealing capability is good and the maximum stress on the body is smaller than the tensile strength. An optimal shape of the dust cover is obtained using the Taguchi method to reduce the maximum stress. The maximum stress of the optimal design under the operation condition is reduced by 22 per cent of that of the initial design. Results of the research show that performance evaluation and design of the dust covers can be effectively done using the proposed method.