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Optimization techniques can be applied to synthesize the design of automotive systems and components to meet product requirements. In this paper, the performance of two automotive designs - a rear suspension system and a clip shape - was improved by using optimization techniques. For each design, calculation of the performance indices and the formulation of the optimization problem are discussed.

A direct method is developed for designing a vehicle fuel filler door with torsional spring. The design parameters include the door's geometrical parameters and spring dimensions. The design requirements are based on the finger force curve during closing and opening, and the bending stress in the spring. An example is included to demonstrate the effectiveness of the new method.