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Based on the example of the development process of the cast suspension of a special-purpose vehicle the application of the integrated engineering design methodology (ICME – Integrated Computational Materials Engineering) and the development of construction has been presented. Identification of the operating and critical loads, which are guidelines for carrying out the structure strength shaping process, material and technological conversion, are due to the needs and requirements of the suspension system and the purpose and objectives of the special mobile platform. The developed cast suspension element construction includes the use of high-strength AlZnMgCu aluminum alloy. The properties of the used alloy and designed shape allows for the transfer of assumed operating loads in normal exploitation conditions and in the dynamic, critical loads to the susceptibility to damage in the assumed casting areas. For the proposed design, conducted numerical analyzes includes the impact of the shock wave pulse on the occurrence of the destructive stress fields. Based on their distribution, the areas of possible decomposition of the structure of the design element were estimated. The results allowed to devise an element with predicted destructions that allow to absorb a significant part of the impact energy of the shock wave front, which is also the buffer zone for the propagation of destruction for the critical kinematic nodes of the system.
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