This research presents the development and implementation of a methodology for rudder design optimization using front-loading. The project has been performed in cooperation with Fokker Aerostructure, which tries to keep up with the increasing competitiveness in the aviation industry. To support this goal, the Knowledge based Rudder and Interface Optimization System (KRIOS) was developed. KRIOS automates the design process of a detailed composite rudder structure, using the existing (in-house developed) Rudder-Generator (RG) and Hinge Design and Optimization Tool (HDOT), which was then wrapped in an optimization framework. KRIOS was verified with and existing rudder, taking into account the model’s current limitations. The developed methodology proposes different optimization strategies that were each studied to assess their benefits and limitations. Thereby, showing how a complex structure like the rudder can be optimized and what strategy achieves a more optimal solution, within a limited amount of time. This helps engineers to increase the product performance of a rudder while reducing the design lead time.