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The continuous demand for reduced development cycles in the light commercial vehicle sector requires highly efficient and integrated engineering workflows. Axle components, particularly the steering knuckle in double wishbone axle systems, must simultaneously withstand severe dynamic loads and meet stringent mass optimization targets. This study proposes a hybrid digital-to-physical development methodology aimed at reducing design iteration time and accelerating prototyping for high-stress automotive components. The approach integrates computer-aided design, finite element analysis, and additive manufacturing within a unified workflow. The geometric model is developed in CATIA, considering packaging constraints and kinematic requirements specific to double wishbone axles. Structural validation is performed through finite element analysis in Ansys under representative load cases, including maximum braking torque, lateral cornering forces, and vertical impact loads. An existing front axle configuration for a light commercial vehicle is used as a case study to demonstrate the applicability of the proposed methodology. Simulation results are used to verify structural performance and ensure compliance with safety factor requirements prior to physical validation. To overcome the cost and time limitations associated with traditional prototyping methods, such as computer numerical control machining and sand casting, additive manufacturing is incorporated into the early validation phase. Rapid prototyping via 3D printing enables fast geometric verification and early detection of integration issues with adjacent components, including brake calipers and wheel hubs. The proposed methodology demonstrates the potential to significantly reduce development time while maintaining structural reliability, supporting faster design iterations and improved manufacturability of critical automotive components.