This research is based on a new hybrid approach, which deals with the improvement of shape optimization process. The objective is to contribute to the development of more efficient shape optimization approaches in an integrated optimal topology and shape optimization area with the help of genetic algorithms and robustness issues. An improved genetic algorithm is introduced to solve multi-objective shape design optimization problems. The specific issue of this research is to overcome the limitations caused by larger population of solutions in the pure multi-objective genetic algorithm. The combination of genetic algorithm with robust parameter design through a smaller population of individuals results in a solution that leads to better parameter values for design optimization problems. The effectiveness of the proposed hybrid approach is illustrated and evaluated with test problems taken from literature. It is also shown that the proposed approach can be used as first stage in other multi-objective genetic algorithms to enhance the performance of genetic algorithms. Finally, the shape optimization of a vehicle component is presented to illustrate how the present approach can be applied for solving multi-objective shape design optimization problems.