The environment and energy related problem has become one of the most important global issues in recent years. One of the most effective ways of improving the fuel efficiency of automobiles is the weight reduction. In order to obtain this goal the hydroforming technology is adapting for the high strength steel and its application is being widened. In present study, the whole process chain of chassis components (cross members) simulation and development by hydroforming technology to apply high strength steel having tensile strength of 440 MPa grade is covered. At the part design stage, it requires feasibility study and process design aided by CAE (Computer Aided Design) to confirm hydroformability in details. Overall possibility of hydroformable chassis parts could be examined by cross sectional analyses. Moreover, it is essential to ensure the formability of tube material on every forming step such as pre-bending, preforming and hydroforming. At the die design stage, all the components of prototyping tool are designed and interference with press is investigated from the point of geometry and thinning.