The accumulation of limescale in steam irons can significantly reduce the ironing efficiency. It is this problem that inspired us to introduce ultrasonic vibrations to irons in order to minimize limescale accumulation. This study describes a methodology for designing, modelling and optimizing an iron fitted with an ultrasonic exciter in an attempt to minimize limescale accumulation. In our methodology, first, an experimental demonstration of the potential benefits of ultrasonic vibrations in steam irons was conducted, using two existing irons, one of which was equipped with an ultrasonic exciter. Having confirmed the benefits, an experimental iron was designed and then optimized to maximise ultrasonic vibrations using finite element analyses within a predefined frequency range. To validate the results of the finite element analyses, a prototype iron base was built, and forced vibrations of this prototype, at ultrasonic frequencies ranging from 35 to 40 kHz, were measured using a laser vibrometer. The results of the theoretical and experimental vibration analyses as well as the physical experiments on the steam irons indicate that it is possible for ultrasonic vibrations to be utilized in irons to minimize the accumulation of limescale.