In this work, the effectiveness of multi-objective design optimization using metamodeling techniques and an internal state variable (ISV) plasticity damage material model as a design tool is demonstrated. Multi-objective design optimization, metamodeling, and ISV plasticity damage material models are brought together to provide a design tool capable of meeting the stringent structural design requirements of today and of the future. The process of implementing this tool are laid out, and two case studies using multi-objective design optimization were carried out. The first was the optimization of a Chevrolet Equinox rear subframe. The optimized subframe was 12% lighter and met design requirements not achieved by the heavier initial design. The second case was the optimization of a Formula SAE front upright. The optimized upright meets all the design constraints and is 22% lighter.