This paper deals with a new product design framework for the optimal structural design applications. The proposed approach called hybrid charged system search (CSS) and Nelder-Mead algorithm (HCSSNM) offers significant improvements in performance over existing methods in the field of computer-aided design optimisation. The HCSSNM based on the CSS and Nelder-Mead algorithm is used for optimisation of a vehicle suspension arm which is critically important for the vehicle safety. As observed in the results, the HCSSNM can be used effectively to reduce the mass of the vehicle components while maintaining its fatigue durability.