Application of Mg alloy parts in automotive industry is increasing to reduce weight and fuel consumption. One of the high potential parts for application of Mg alloys is the front seat frame. However, change of material is accompanied by change of manufacturing process and change of design for the seat frame. In the present research while keeping the reference overall ergonomic outline, a new substitute Mg alloy design was proposed, featuring a simple easy to manufacture Z profile. Next, a two-stage optimization technique (size and shape) is proposed for the Mg seat frame based on the stress and displacement criteria of standard test plans. The final optimized design is close to fully-stressed state and is 70% lighter than the reference steel backrest.

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