For the purpose of dealing with uncertainty factors in engineering optimization problems, this paper presents a new non-probabilistic robust optimal design method based on maximum variation estimation. The method analyzes the effect of uncertain factors to objective and constraints functions, and then the maximal variations to a solution are calculated. In order to guarantee robust feasibility the maximal variations of constraints are added to original constraints as penalty term; the maximal variation of objective function is taken as a robust index to a solution; linear physical programming is used to adjust the values of quality characteristic and quality variation, and then a bi-level mathematical robust optimal model is constructed. The method does not require presumed probability distribution of uncertain factors or continuous and differentiable of objective and constraints functions. To demonstrate the proposed method, the design of the two-bar structure acted by concentrated load is presented. In the example the robustness of the normal stress, feasibility of the total volume and the buckling stress are studied. The robust optimal design results show that in the condition of maintaining feasibility robustness, the proposed approach can obtain a robust solution which the designer is satisfied with the value of objective function and its variation. For the purpose of dealing with uncertainty factors in engineering optimization problems, this paper presents a new non-probabilistic robust optimal design method based on maximum variation estimation. The method analyzes the effect of uncertain factors to objective and constraints functions, and then the maximal variations In order to guarantee robust feasibility the maximal variations of constraints are added to original constraints as penalty term; the maximal variation of objective function is taken as a robust index to a solution; linear physical programming is used to adjust the values ​​of quality characteristic and quality variation, and then a bi-level mathematical robust optimal model is constructed. The method does not require presumed probability distribution of uncertain factors or continuous and differentiable of objective and constraint functions. To demonstrate the proposed method, the design of the two-bar structure acted by concentrated lo In the example the robustness of the normal stress, feasibility of the total volume and the buckling stress are studied. The robust optimal design results show that in the condition of maintaining feasibility robustness, the proposed approach can obtain a robust solution which the designer is satisfied with the value of objective function and its variation.