Advanced Non-linear topology optimization methods have been addressed as the most promising techniques for light weight and performance design of Powertrain structures. The theoretical achievements are obtained both mechanically and mathematically. Nowadays, the great challenge lies in solving more complicated engineering design problems with multidisciplinary objectives or complex structural systems.The purpose of this paper is to provide a forum to present new developments in structural Non-linear topology optimization. The advantage of the proposed method is that structural optimization on irregular design domains can be carried out easily. Furthermore, this method integrates the stress analysis and the boundary evolution within the framework of finite element methods.In this paper, mainly focused on the Commercial Vehicles Powertrain component i.e. Transmission Housing. To achieve same existing/proven Cast Iron Housing stiffness for new Aluminium Housing stiffness with defined worst gear loading conditions. For this, I have used Non-linear Topology Optimization technique with the help of Simulation tool Altair OptiStruct and Its Experimentally Verified under worst Gear Loads.