AbstractAn efficient method is developed for sensitivity analysis in shape optimization of axisymmetric structures. The technique of isoparametric mapping is used to generate the finite element mesh from a small set of master elements and master nodes. Co‐ordinates of selected master nodes are used as design variables. Shape function values of master elements at derived finite element nodes obtained during the isoparametric mapping process are utilized to calculate the gradients of weight and response of the structures with respect to the design variables. Analytic formulations of the gradients are developed for sensitivity analysis of axisymmetric structures. An optimization procedure using a sequential linear programming method is applied to effectively utilize the calculated gradients. Numerical examples of optimum design of disks subject to thermo‐mechanical loadings are presented.