Fatigue failure is a significant challenge in welded structures, particularly in forkliftreinforcements subjected to cyclic loading. This study aims to optimize the design andwelding configurations of steel reinforcements to enhance fatigue life and reduce stressconcentrations at critical weld locations. The research involves numerical analysis usingFinite Element Method (FEM) simulations, hand calculations, and topology optimization toassess and improve the structural performance of welded structures.A comparative analysis is conducted between a baseline model without reinforcement and animproved design incorporating welded stiffeners. Initial results indicate that reinforcementsignificantly reduces stress concentrations, thereby increasing fatigue resistance. FEMsimulations and analytical calculations are used iteratively to validate the structural integrityand determine the optimal reinforcement configuration.Furthermore, the study investigates whether weld sizes can be reduced in laser-cut steelreinforcements without compromising fatigue strength. Design recommendations aredeveloped based on guidelines from SSAB, Eurocode, and IIW standards. The outcome isexpected to provide a refined reinforcement design that enhances durability and performancewhile optimizing material usage and manufacturing costs.This research employs an Agile methodology, ensuring continuous improvement throughiterative cycles of design, analysis, and validation. The results contribute to the developmentof optimized forklift reinforcements, offering a practical solution for fatigue-related failures inheavy-duty industrial applications.