One of several challenges while dimensioning components of handling systems is the consideration of force and torque influences acting during operation in the correct order of magnitude based on the process used. With existing design approaches dynamic loads in particular are usually not adequately taken into account and therefore high safety factors are selected. However, this also increases the weight and usually the costs. To reduce over-dimensioning, this paper presents a methodical approach for dimensioning and structural optimization of components. The method combines a multi-physical simulation and finite element analysis to improve the design of components, considering the process-related forces and moments applied to the system boundaries. These are calculated in the multi-physical simulation and transferred to an FEM simulation, where they are used to optimize the component's design and structure. The approach of distributed simulation helps to reduce the over-dimensioning of components and improve the development process of assembly system components.