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In my study, designing and modeling the heavy vehicle chassis is done using Pro/Engineer software, taking the data from the L & T Heavy vehicle model by reverse engineering processes. The shear strength of chassis is determined theoretically and compared with FEA analysis. The shape of the heavy vehicle chassis is optimized by taking C ± Channel, Box Section and I Section. And also optimization is done to reduce the weight of frame on the chassis. Present used material for chassis is Carbon steel. Replacing the chassis material with Kevlar fiber and S+R(Strength+Rigidity) Glass. By using steel, the weight of the chassis is more compared with Kevlar fiber and S+R Glass Epoxy, since its density is more. FEA analysis is done on chassis for optimizing above parameters under 10 tons load.