This paper has tried to apply the response surface approximation method in the structural optimization techniques to develop aluminum beverage can ends. Geometrical parameters of the end shell are selected as design variables. The analysis points in the design space are assigned using an orthogonal array in the design-of-experiment technique. A finite element analysis code is used to simulate the deforming behavior such as the buckling strength and central panel displacement of the end shell under internal pressure. On the basis of the numerical analysis results, the response surface of the buckling strength and panel growth are approximated in terms of the design variables. By using a numerical optimization program, the weight of the end shell is minimized subject to constraints of the buckling strength, panel growth suppression and the other design requirements. A numerical example on 202 end shell optimization problem has been shown in this paper. (c) 2006 Elsevier Ltd. All rights reserved.