A Design of Experiment (DoE) based methodology is proposed for use in optimising sailing mast structures. The method uses Finite Element Analysis to simulate mast behaviour when subject to typical design loadings. Due to the large number of possible combinations of design variables the use of a fractional factorial selection is used to determine their values for the limited number of simulations required. The analysis is based around a mast for use with the Mini Transat 6.50 class of yacht and provides a suitable challenge when compared to the typically conservative approach used in mast design. The mast structure is considered with respect to standing rigging working loads and spreaders geometry on the deformed shape of a pretensioned mast. Responses in terms of maximum value of mast camber, position of mast camber and generalized distance from optimal curves are provided, response surfaces over design variables domains are built and the most influential parameters are selected. Moreover, the present approach allowed us to provide combinations of parameters leading to optimal matching between a given target curve and the shape of a pretensioned mast.