CC BY 4.0Busch, AlexanderAlexanderBuschBruch, OlafOlafBruchReith, DirkDirkReith2025-10-272025-10-272025https://publica.fraunhofer.de/handle/publica/497783https://doi.org/10.24406/publica-589410.3390/polym1719269710.24406/publica-58942-s2.0-105018912487Reducing material usage in plastic products is a key lever for improving resource efficiency and minimizing environmental impact. In thin-walled structures subjected to mechanical loading, material efficiency must be achieved without compromising structural performance. In particular, resistance to buckling, a critical failure mode, must be taken into account during product development. Due to the large number of design and process variables, many of which are interdependent, optimization approaches are uncommon in the blow-molded packaging industry. This paper presents a sensitivity-based optimization approach to improve buckling resistance by modifying the product’s material distribution. Since the sensitivity is nonlinear and depends on the product’s deformation state, various methods are developed and tested to reduce the frame-wise sensitivity data to a single sensitivity vector suitable for optimization. These methods are then tested on common extrusion blow-molded products, achieving improvements in buckling load of up to 60%. This approach is transferable to other thin-walled structures across various engineering domains, offering a pathway toward lightweight yet load-compliant designs.entrueenhancing buckling resistanceextrusion blow moldinghigh-density polyethylenenonlinear structural optimizationsensitivity-based optimizationthin-walled structuresjournal article