In the quest for sustainability in industrial design, the automotive sector stands at the forefront, where enhancing component durability and performance is paramount. This paper presents a novel design approach for automotive suspension systems, leveraging additive manufacturing techniques to achieve significant improvements in both sustainability and mechanical behavior. The introduced design innovation encompasses substantial changes, notably the incorporation of a new joint arm manufactured additively. This departure from traditional manufacturing methods, such as sheet metal forming, not only reduces component weight but also enhances design flexibility. Alongside geometric modifications, optimization of design parameters like track width aims to deliver a sportier driving experience while maintaining vehicle stability and comfort. The design approach ensures stress and displacement levels comparable to the original design. Static numerical analysis demonstrates superior mechanical behavior, with a noteworthy 55% reduction in displacement compared to the original design. Moreover, the new design significantly reduces the vehicle's unsprung mass, positively impacting overall performance and efficiency. These findings underscore the potential of additive manufacturing as a catalyst for advancing sustainability in automotive component design. By optimizing both current and discontinued products in terms of performance, durability, and environmental responsibility, additive manufacturing offers new avenues for meeting the evolving demands of modern transportation while minimizing ecological footprint.