Optimising stope support design is crucial in mining engineering to ensure underground safety and stability. Traditionally, rock mass classification methods have guided support strategies, but they come with inherent limitations. This study takes a novel approach by adopting support resistance design criteria, providing a more effective alternative. Using advanced numerical modelling techniques, the research evaluates stope support systems by considering key factors such as geomechanical properties, stope geometry, and support configurations. The study specifically examines three primary failure modes wedge failure, block failure, and spalling through simulations that replicate real-world mining conditions. By integrating empirical data with sophisticated analytical tools, the research accurately determines support resistance requirements, ensuring structural reliability and minimising failure risks. The optimised design, tailored to local geological conditions, significantly enhances worker safety and operational resilience by reducing the likelihood of support failures. A comprehensive economic analysis indicates that while the initial implementation costs are slightly higher, the long-term advantages such as reduced downtime, fewer ground falls, and improved safety protocols far outweigh the investment. This approach strikes a balance between economic feasibility and operational sustainability by prioritising durable and effective support systems. By moving away from traditional methodologies, this study highlights the need for innovative strategies in stope support design, ultimately contributing to safer, more efficient, and sustainable mining practices. The findings also promote resource optimisation, reducing unnecessary support material usage and mitigating the need for ground fall reclamation.