A statistical approach with D‐optimal design was used to optimize the process parameters for polycaprolactone (PCL) synthesis. The variables selected were temperature (50°C‐110°C), time (1‐7 h), mixing speed (50‐500 rpm) and monomer/solvent ratio (1:1‐1:6). Molecular weight was chosen as response and was determined using matrix‐assisted laser desorption/ionization time of flight (MALDI TOF). Using the D‐optimal method in design of experiments, the interactions between parameters and responses were analysed and validated. The results show a good agreement with a minimum error between the actual and predicted values.