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The wood industry faces the dual requirements of improving the quality of timber products and minimising waste during the manufacturing process. The finger joint, which is an end-to-end joining method for timber boards, is one of the most important aspects of engineering wood products. This study presents a numerical and optimisation investigation of the effects of finger-joint design parameters on the flexural behaviour of finger-jointed timber beams. A numerical model based on advanced three-dimensional finite element analysis was developed to model the behaviour of finger-jointed beams. Using the validated finite element (FE) model and automated parameterisation, a parametric study was conducted to assess the impact of each design parameter of the finger joint, including finger length, tip thickness, and the number of finger joints. The results indicate that the number of fingers and finger length significantly influence the maximum load capacity, while the tip thickness has a marginal effect on performance. This study identifies a design threshold of five fingers and a 14 mm finger length for achieving efficient, high-performance finger-joint designs. In addition, the multi-objective modified firefly algorithm (MOMFA) was proposed to maximise the finger joint resistance while simultaneously minimising the material waste. The optimisation shows that there will be a significant amount of wood waste when using traditional single-objective optimisation that only focuses on structural performance. In contrast, the proposed method achieves comparable load capacity while significantly reducing waste (up to 53.31%) during the joining process. The …