Structural design optimization under impact loading faces two difficulties. First, the inherent complexity of the finite element model required for modeling the complicated physical phenomenon, and second the high computational cost required by the iterative nature of numerical optimization. This paper presents a practical approach for solving this problem by using the response surface method as an approximate model rather than the computationally expensive one. Then numerical optimization can be conducted at an affordable computational cost. Finally, only one simulation analysis is conducted using the initial finite element model to verify the optimum design achieved from numerical optimization. The proposed approach has been successfully applied to the problem of designing a thin walled tube under impact loading which suggests that this approach can be used for solving design optimization problems of other complex structures.