Double-deck train has been attracted growing attention as next generation transportation around metropolis because of high passenger carrying capacity. To develop high-speed double-deck train with low operational costs, the carbody must be designed as light as possible. In addition, the carbody must be strong enough to ensure the safety of passengers. To meet these design requirements, we perform systematically weight minimization that determines thickness of aluminum extruded panels of the carbody. First, to reduce the design variables, we carry out the screening process that select sensitive or/and important design variables through design exploration. Then, weight minimization is accomplished under multi-loading condition such as vertical, compressive and torsional loads, while satisfying strength constraints of the design regulations. Finally, the result of design optimization is discussed by comparison with its initial design.