The paper proposes the fuzzy logic global approximate optimization strategies in optimal sizing of automotive A-pillar trim with rib structures for occupant head protection. Two different strategies referred to as evolutionary fuzzy modeling (EFM) and neuro-fuzzy modeling (NFM) are implemented in the context of global approximate optimization. EFM and NFM are based on soft computing paradigms utilizing fuzzy systems, neural networks and evolutionary computing techniques. Such approximation methods may have their promising characteristics in a case where the inherent nonlinearity in analysis model should be accommodated over the entire design space and the training data is not sufficiently provided. The objective of structural design is to determine the dimensions of rib in A-pillar, minimizing the equivalent head injury criterion HIC(d). The paper describes the head-form modeling and head impact simulation using LS-DYNA3D, and the approximation procedures including fuzzy rule generation, membership function selection and inference process for EFM and NFM, and subsequently presents their generalization capabilities in terms of number of fuzzy rules and training data.