<p>This paper presents a novel method for structural lightweight design of automotive safety components, exemplified by the aluminum alloy steering knuckle. This study aims to lightweight the aluminum alloy steering knuckle while ensuring its critical performance indicators remain unaffected through advanced computer-aided design and simulation analysis techniques. A finite element model is developed and subjected to comprehensive simulations under realistic load conditions to evaluate strength, stiffness, modal characteristics, and fatigue durability. With weight minimization and first-order modal frequency maximization as objectives, through rigorous sensitivity analysis, the structural size parameters of the aluminum alloy steering knuckle that significantly influence the target responses, including weight, modal frequency, and stress distribution, were identified as design variables. Based on this, a high-precision response surface model was constructed, and the Non-dominated Sorting Genetic Algorithm II (NSGA-II) was integrated for multi-objective optimization design. The resulting optimal design achieves a 5.6% weight reduction while maintaining all performance criteria, demonstrating the algorithm's effectiveness in automotive safety component lightweighting. This study not only provides a scientific basis and technical support for the lightweight design of automotive suspension systems but also showcases the immense potential of advanced simulation optimization techniques in enhancing automotive component performance and reducing costs.</p>