Design productivity plays a crucial role in the development of large-scale mechanical systems because of the involvement of a great amount of resources, long life cycle, and multi-disciplinary teams. At the early stage parametric design, the generation and evaluation of robust design alternatives are expected at the least expense. In this paper, a direct synthesis (DS) method is presented. With simultaneous consideration of negotiability, bi-directional robustness, and efficiency in a “Zoom-in” process, the DS can facilitate the quick synthesis of robust design alternatives without resorting to numerous iterations. The preliminary industrial application results of the Direct Synthesis method show its effectiveness for robustness enhancement and cost reduction at the early stage parametric design of a vehicle structural system.

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