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Abstract Recently, there has been a growing focus on understanding material behaviors to improve product designs in the oil and gas (O&G) industry. This paper aims to apply fracture mechanics principles to predict the stress and strain state of rubber when feeding lines through splice-less swellable packers. Specifically, various rubber elastomer shapes are examined through Finite Element Analysis (FEA) in ABAQUS/Explicit, guided by experimental data. The fracture damage mechanism of rubber is more complex compared to metallic parts, and it is crucial for ensuring product reliability. In cased or open-hole environments, swellable systems with cable feedthroughs are utilized to achieve zonal isolation of producing zones during downhole operations. A dedicated tool has been developed to facilitate cable installation during the feedthrough process. To have a better understanding of hyper-elastic behavior in rubbers at large deformations and identify optimal geometrical designs, FEA is conducted in ABAQUS/Explicit, coupled with a user subroutine (VUSDFLD). Test results are used to calibrate the material properties, enabling a comprehensive representation of the material behavior under damage conditions. The experimental model is replicated by a finite element model based on the comparison of measured and calculated forces acting onto the rubbers. Similar deformation patterns are observed. In the numerical model, the initial development is based on maximum principal strain-based crack initiation, with element removal utilized to approximate the damage initiation and evolution. With such a calibrated numerical model, four different geometries are examined: circular, square, trapezoidal, and winged shapes. The optimal design is determined based on achieving the lowest load to stroke the same displacement while minimizing the volume of rubber with higher strain state. It's found that the optimal shape is the winged shape, significantly reducing peak principal strain around the hole boundary compared to typical circular profiles. In summary, fracture mechanics principles are studied and applied in the numerical analysis to predict the stress and strain states of rubbers and provide guidelines in the tool designs in cable feedthrough installations. This approach ensures enhanced reliability of cable systems, crucial for risk reduction during completion system installations.