The ongoing drive for lighter and more efficient structural components by the commercial engineering industry has resulted in the rapid adoption of the finite element method (FE) for design analysis. Satisfied with the success of finite elements in reducing prototyping costs and overall production times, the industry has begun to look at other areas where the finite element method can save time, and in particular, improve designs. First, the mathematical methods of optimisation, on which the methods of structural design improvement are based, are presented. This includes the methods of: topology, influence functions, basis vectors, geometric splines and direct sensitivity methods. Each method is demonstrated with the solution of a sample structural improvement problem for various objectives (frequency, stress and weight reduction, for example). The practical application of the individual methods has been tested by solving three structural engineering problems sourced from the automotive engineering industry: the redesign of two different front suspension control arms, and the cost-reduction of an automatic brake tubing system. All three problems were solved successfully, resulting in improved designs. Each method has been evaluated with respect the practical application, popularity of the method and also any problems using the method. The solutions presented in each section were all solved using the FE design improvement software ReSHAPE from Advea Engineering Pty. Ltd.