This paper details the use of the Thyssenkrupp eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. eDICT uses the optimisation capability of Optistruct with a set of custom tools to guide and translate a design into a production feasible sheet metal solution. Fundamentally it reverses the usual design loop of CAD first then CAE assessment. The function is used to determine the design and the form follows. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.