"The remarkable and unique mechanical properties of natural structural designs have always been a source of inspiration for scientists to enhance material design. The integration of bioinspired design with topology optimization promises unprecedented possibilities in terms of improving the properties and functionalities of products. Recently, the advancement in additive manufacturing has enabled the sustainable and accurate fabrication of complex designs that were not possible a decade ago, which opened the door to implement and develop material design optimization methods. Aiming to understand and enhance design optimization methods towards the advancement of sustainable product design, the present dissertation systematically examined various optimization techniques and their implementation in real-life applications with a focus on a bioinspired approach. The dissertation involves design optimization through both analytical modeling and finite element analysis (FEA). Uniaxial tension and compression experiments were conducted on additively manufactured specimens to validate the results obtained from the different investigated design optimization models. The dissertation is manuscript-based containing three inherently connected articles (see the first page in chapters 3-5 for the interconnectivities). Chapters 3 covers design optimization through analytical modeling with a focus on optimizing the design of circumferential clasps in additively manufactured removable partial dentures. Chapter 4 presents bioinspired shape optimization with mesh adaptive direct search to improve strength and stiffness of metal/polymer interfaces in additively manufactured dental prostheses. Chapter 5 introduces an optimization framework for bioinspired topological design coupled with probability distribution models to generate the initial guess. Through this framework, bioinspired and optimized cellular structures could be designed for various biomedical and engineering applications. The aforementioned studies offer new insights to leverage the potential of additive manufacturing and optimize the mechanical design of structures and interfaces"--