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PurposeThis study aims to propose a complete and powerful methodology that allows the optimization of the passive suspension system of vehicles, which simultaneously takes comfort and safety into account and provides a set of optimal solutions through a Pareto-optimal front, in a low computational time.Design/methodology/approachUnlike papers that consider simple vehicle models (quarter vehicle model or half car model) and/or simplified road profiles (harmonic excitation, for example) and/or perform a single-objective optimization and/or execute the dynamic analysis in the time domain, this paper presents an effective and fast methodology for the multi-objective optimization of the suspension system of a full-car model (including the driver seat) traveling on an irregular road profile, whose dynamic response is determined in the frequency domain, considerably reducing computational time.FindingsThe results showed that there was a reduction of 28% in the driver seat vertical acceleration weighted root mean square (RMS) value of the proposed model, which is directly related to comfort, and, simultaneously, an improvement or constancy concerning safety, with low computational cost. Hence, the proposed methodology can be indicated as a successful tool for the optimal design of the suspension systems, considering, simultaneously, comfort and safety.Originality/valueDespite the extensive literature on optimizing vehicle passive suspension systems, papers combining multi-objective optimization presenting a Pareto-optimal front as a set of optimal results, a full-vehicle model (including the driver seat), an irregular road profile and the determination of the dynamic response in the frequency domain are not found.