In design of magneto-rheological brake (MRB), it is well-known that the shape of the brake envelops significantly affects to performance characteristics of the brake. In this study, different shapes of MR brake envelop such as rectangular and polygon shape of the envelope are considered from which the most suitable shape is identified. After an introduction of MRBs with different envelop shapes, the braking torque of the brake is derived based on Bingham-plastic behavior of the magneto-rheological fluid (MRF). Optimal design of the MRB with different envelop shapes is then performed. The optimization problem is to find optimal value of significant geometric dimensions of the MRBs that can produce a required braking torque while their mass is minimized. A finite element analysis integrated with an optimization tool is employed to obtain optimal solutions of the MRBs. From the results, the most suitable shape of the brake envelop is identified.