This paper presents an efficient method and the corresponding software for automatic concept design and optimization of twist beam axles. With this method, it is possible to evaluate and optimize a concept of twist beam axles in terms of 40 important concept variables and 12 typical axle properties within a few minutes without using CAD and CAE. This work also discusses some original and new knowledge about twist beam axles with sensitivity analyses. Furthermore, this work reports a successful utilization of mathematical algorithms based on nonlinear vector optimization with constrains for a realistic and industrial problem. This approach has a very good potential for other similar mechanical systems.