A drop test simulation of the mechanical structure of a redesigned dishwasher is performed by using a detailed finite element (FE) model. The nonlinear explicit FE code LS-DYNAA (R) is used for the drop impact simulations. The FE model is validated through real tests of two drop scenarios (vertical and inclined to the side). An optimization study is performed in order to determine the optimum design variables for better crash performance. The effects of geometric parameters and material properties on the weights of certain components (ie, dogleg plate and bottom foam) are investigated. A surrogate-based optimization approach is used to find optimum values for the dogleg plate thickness, bottom foam density and increment of the bottom foam height to minimize the weights of both components. Two different surrogate models are used to predict optimization problem constraints that have a crucial role in the crash performance of the dishwasher mechanical structure and packaging module: the polynomial response surface and radial basis functions. The results showed that the dogleg plate mass can be slightly reduced and the bottom foam mass can be significantly reduced in order to obtain the optimum dishwasher configuration and better crashworthiness. The weights of the dogleg plate and bottom foam could be lowered by as much as 5.95 and 24.8 %, respectively. Finally, multi-objective optimization is performed by minimizing a composite objective function that provides a compromise between the weights of both components. The results showed that weight reductions of 2.3 and 21.5 % could be obtained for the dogleg plate and bottom foam, respectively.