The FEA method and hand calculations activities done for the design to optimize the weight and cost while providing adequate factor of safety .Design modeler was used to construct a 3D model of the pedal crank and initially produced solution using simple representations of loads and restrains and default mesh produced. Model was solved until receive converged result of equivalent stress and directional deformation. Design was validated using hand calculated values and FEA values. There are some deviations only in equivalent stress and directional deformation was almost correct. Finally high stress points were identified and design changes/