This study employed two primary approaches to determine the optimum structure: the lightweight and sustainable models. The lightweight model considered various factors such as materials, geometry, and dimensions of the brake disc rotor and brake pads. On the other hand, the sustainable model considers the manufacturing process and aims to reduce the carbon footprint. To calculate the optimal lightweight structure, finite element analysis was conducted using two different materials to compare the resulting stresses and determine the most appropriate material. Subsequently, four different models were utilized in finite element analysis to evaluate the displacement and stress and establish the optimum structure. Regarding sustainability, two distinct processes were employed to assess the environmental impact and energy consumption to adopt an eco-friendly approach. This paper investigates the transition from the initial brake disc rotor to a lightweight model, employing finite element analysis, topology optimization, and sustainability considerations. The work is achieved by comparing the cost between conventional and 3D printing processes.