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The method of fatigue life evaluation and validation testing under operational conditions is a prerequisite to achieve optimal designs with respect to weight and long-term durability of the structure considered. Criteria like driving behavior and braking performance, influenced by global stiffness as well as fatigue life evaluation were taken into account when optimizing a forged 6.5 front axle beam of a heavy truck. The procedure for weight optimization includes the following steps: Stress analysis e.g. using strain gage techniques and/or Finite Element Method, Road load data acquisition and derivation of design spectrum describing customer usage, Fatigue testing under constant amplitude and/or variable amplitude loading to establish component related SN-curves and/or fatigue life curves, Fatigue life evaluation using damage accumulation hypothesis (Miner's Rule), Optimization and weight reduction (in this case 14% weight savings were achieved) based on fatigue life evaluation.