FEA-Optimised Zirconia Geopolymer Ceramic is a high-performance, thermally stable material developed from kaolin geopolymer reinforced with ZrO₂. Optimised sintering (800–1200 °C) enhances densification and reduces porosity. FEA validates stress, thermal load, and crack behaviour, improving strength and stability. With 7.5 wt% ZrO₂, it offers superior phase stability, efficiency, and suitability for thermal barriers and high-temperature engineering applications.