In this article, taking the design for brake shell of passenger car of a company for example, combining structural optimization technology, integrating the factors of optimizing design requirements, space requirements of the system, molding process and cost analysis. Integrate topography optimizing, then stamp process technology and the layout requirements of the brake shell. Formed a technology road-map of the structural optimization of the brake shell and carried out an optimal-design method. Solved problems of the previous design for the brake shell (repeated cycle between design and simulation analysis) whose cycle is long and the results are not ideal.