Robust design theories and methods have been widely implemented in automobile design. However, most of the existing studies on the robust design for vehicle merely consider the uncertainties in structural sizes of components, while those in weld and material have not been well studied in an integrated manner. This research proposes a robust design framework which can incorporate various sources of uncertainties. Several major steps are included in the proposed framework: uncertainty quantification based on test and maximum likelihood estimation, weld significance analysis and robust design based on metamodel. Uncertainties in material properties and joint strength are quantified by test and statistical approach. Weld significance analysis is employed to find out the welds which will greatly affect the interest performances. Metamodel contributes to improving the efficient of robust design. The proposed framework is successfully demonstrated through a vehicle front structure design optimization. The results show that the implementation of the proposed method which considers uncertainties of material, weld and structural size can effectively reduce the weight of vehicle while satisfying the safety constraints.

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