To solve the problems of automotive wheel’ design by using traditional methods, application of finite element analysis in modern automotive wheel design is presented. Then, for example of SU0011-typed aluminum alloy wheel, this paper illustrates in detail the application in its hub structure design, mold design and casting process. By using the ANSYS software, structural design of wheel is optimized according to the CAE results of fatigue strength. In the meanwhile, the casting mold of wheel hub is also designed. Using the ProCAST software, casting process optimization and casting defects elimination can be realized based on simulating the process of filling and solidification of low-pressure casting. Experimental analysis shows that, with the help of finite element analysis, design accuracy and product reliability can be effectively improved and product development cycles can be greatly shorten. So the application has a very good prospect in the automotive industry.