Abstract The development of new methods in analysing package designs using the finite-element method is of increasing importance. Package designers are increasingly applying the growing opportunities afforded by numerical methods to perform safety assessments for their products; this also requires suitable methods for competent authorities like BAM to verify applicants' results. This paper gives a topical overview of experiences and trends within the complex field of finite-element design testing. First some general and more formal aspects are described concerning the selection of the correct finite-element program and documentation of modelling, material properties, boundaries and calculation results, including their interpretation. To give a reliable basis for applicants in Germany BAM has recently drawn up and published a Finite Element Guideline. Secondly, actual technical questions are discussed: these are of wide interest and range from mechanical reflections on cask drop and extreme impact scenarios to thermal reflections on the removal of decay heat and fire scenarios. Examples from BAM's work on finite-element development activities are given to demonstrate the great opportunities as well as the difficulties of using finite-element methods for package safety analysis and design testing.