The gudgeon pin is one of the engine's most stressed components. Gudgeon pins are used in automotive engines to link the piston and connecting rod. Stress concentration is a critical concern in the design of mechanical components, as it can lead to premature fatigue failure and, consequently, catastrophic consequences. To mitigate this risk, engineers continually seek ways to optimize the design of components like the gudgeon pin, and one avenue of exploration is the judicious choice of materials. This study looks at the detailed design and analysis of existing gudgeon pins in order to detect the pin's stress concentration and then minimize it by making necessary changes to the pin's design and mounting. The current work involved constructing a gudgeon pin and then using finite element analysis (FEA) software to examine and minimize stresses on the pin. This comprehensive study delves into the intricate world of gudgeon pin design and analysis, with a specific emphasis on minimizing stress concentration by selecting different materials through FEA.