The automotive industry faces many competitive challenges including weight and cost reduction to meet need for higher fuel economy. It is a trend that a lot of parts have been currently changed to an aluminum alloy from steel materials. It is required more precise analysis for practical load because of complexities and varieties of vehicle structure. In this study, the shape optimization using a FEA is performed to determine the design of the knuckle. The size optimization is carried out to find thickness while the stiffness constraints are satisfied. A commercial optimization software MSC/NASTRAN is utilized for the structural analysis and the optimization processes.