Weight is one of the important design drivers of automotive members. In case of primary load bearing members such as the chassis, the design process is driven by numerous manufacturing and performance conditions. As a result weight saving efforts can only be taken up in later design cycles rather than in the preliminary ones. A robust optimization approach would lead to weight savings without significant deterioration in performance. The size optimization runs are carried out on the actual chassis frame. The chassis was analysed from various perspective. The FE model is created using...