A general approach for the construction of global approximations to structu
ral behaviour using response surface methodology is presented. The computat
ion and use of these approximations are demonstrated using a semi-solid tyr
e example. The use of these global approximations to the responses made it
viable to utilise the capabilities of non-linear analysis software in desig
n optimisation. The insight gained from a preliminary low fidelity model wa
s utilized in a two-stage approach to achieve the maximum benefit from a mo
re expensive high fidelity model. The resulting high-accuracy approximation
s greatly reduced the cost of subsequent design calculations such as multid
isciplinary and discrete optimisation.