Optimisation of the geometry (curvature of the vitrified enamel layer) of a laser-generated single-stage ceramic tile grout seal has carried out with a finite element (FE) model. The overall load bearing capacities and load-displacement plots of three selected geometries were determined experimentally by the indentation technique. Simultaneously, a FE model was developed utilising the commercial ANSYS package to simulate the indentation. Although the load-displacement plots generated by the FE model consistently displayed stiffer identities than the experimentally obtained results, there was reasonably close agreement between the two sets of results. Stress distribution profiles of the three FE models at failure loads were analysed and correlated so as to draw an implication on the prediction of a catastrophic failure through an analysis of FE-generated stress distribution profiles. It was observed that although increased curvatures of the vitrified enamel layer do enhance the overall load-bearing capacity of the single-stage ceramic tile grout seal and bring about a lower nominal stress, there is a higher build up in stress concentration at the apex that would inevitably reduce the load-bearing capacity of the enamel glaze. Consequently, the optimum geometry of the vitrified enamel layer was determined to be flat
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