This paper reports how the stiffness of a Flat Spring can be predicted using nonlinear Finite Element Analysis (FEA). The analysis of a Flat Spring is a nonlinear problem involving contact mechanics, geometric nonlinearity and material property nonlinearity. Research has been focused on improving the accuracy of the model by identifying and exploring the significant assumptions contributing to errors. This paper presents results from some of the models developed using FEA software. The validation process is shown to identify where improvements can be made to the model assumptions to increase the accuracy of prediction. The goal is to achieve an accuracy level of 10 % as the intention is to replace practical testing with FEA modelling, thereby reducing the product development time and cost. Results from the FEA models are compared with experimental results to validate the accuracy.