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This paper discusses the requirement for CAE methods to properly take into account the variabilities and uncertainties that characterizes design input properties without leading to oversized structures. Optimizing the structural behaviour while taking into account expected variability and uncertainty in the structure and its model, requires the adoption of a reliability-based design optimization approach. This paper starts with an overview of the problem of simulation uncertainty. The key focus is then on the description of the most commonly used methods and enabling tools for reliability analysis and reliability based design optimization. The theory is illustrated by real automotive design problems.