Abstract This work proposed a new metaheuristic dubbed as Chaotic Lévy flight distribution (CLFD) algorithm, to address physical world engineering optimization problems that incorporate the chaotic maps in the elementary Lévy flight distribution (LFD). Hybridization aims to increase the LFD rate of convergence while also providing a problem‐free optimization approach. The proposed methodology is investigated for five case studies of constrained optimization issues followed by shape optimization of structural design. The outcomes from the CFLD algorithm are further contrasted with its fundamental version and other distinguished recently introduced algorithms. The computational analysis illustrates the dominance of CLFD over other considered optimizers. Moreover, the present investigation shows that CLFD is a robust technique that can efficiently find optimal mechanical design problems with a proper chaotic map selection.

Abstract Structural design and optimization are important topics for the control and design of industrial robots. The motivation behind this research is to design a robot gripper mechanism. To explore robust design of the robot gripper mechanism, a new optimization approach based on a grasshopper optimization algorithm and Nelder–Mead algorithm is developed for requiring a fast and accurate solution. Additionally, a vehicle side crash design problem, a multi‐clutch disc problem, and a manufacturing optimization problem are solved with the developed method to show the advantages of the new technique (HGOANM). Both engineering comparisons and production problem results in which HGOANM is applied are compared with the latest optimization techniques in the literature. The results of the problems resolved in this article reveal that the developed HGOANM is an essential optimization approach by solving real‐world engineering problems quickly and accurately.