This paper discusses the application of Taguchi method integrated with response surface methodology (RSM) in minimizing the wear of polycrystalline diamond compact (PDC) cutter through geometry optimization. The Taguchi experimental design has been used to run the simulation. The geometry factors used are chamfer angle, back rake angle, side rake angle and cutter diameter. The influence of geometry on wear is investigated and the optimal geometry to minimize the wear is obtained. A second-order model between the geometry factors and wear has been developed by using RSM. The simulation results show that the side rake angle is the most significant factor influencing the wear followed by back rake angle, cutter diameter and chamfer angle accordingly. The predicted values and simulated values are observed to be fairly close, which indicates that the developed model can be effectively used to predict the wear in PDC cutter. The predicted values are confirmed by using validation tests. © 2018 Author(s).