Air intake system (AIS) plays an important role on affecting the performance of the engine and the vehicle. The design and optimization of the structures and materials of AIS contributes to producing a quality reliable system, reducing noise, cost and weight at the same time, which are significant to improve the performance of engine and vehicle. Fresh air hoses/pipes are intended to transport, in air cleaner purified, air from the air cleaner to the throttle fitted on the inlet manifold or to the compressor fitted to the exhaust manifold. Air cleaner box is responsible for filtering out the dust and impurities in the air. The charge air pipes are intended to transport purified compressed air from the compressor to the charge air cooler and then to the throttle fitted on the inlet pipe. For the air cleaner box optimization, through the benchmarking and the innovation ideas from the daily life, two alternative optimized designs were introduced to reduce the cost and weight. The first is four clips connectors and the other is spring clamps. For the hose clamps, another innovation design was introduced to replace the previous hose clamps, which is called friction connector on the inner side of the bellow hose, the outer side of the air cleaner box lid and the clean side duct. For the material of the charge air ducts, TPEE was selected to replace the previous EACM rubber hoses. Further tests and prototypes should be conducted and produced to verify the effect of the optimization.