In this research, an application algorithm, which can be used in computer-aided design/engineering (CAD/CAE) and structural optimisation-based design studies of agricultural machineries, is introduced. This developed algorithm has been put in practice in a case study for a tractor mounted telescopic boom crane. The algorithm consists of both numerical and experimental methods and it includes material testing, three-dimensional (3D) computer-aided design and finite-element method (FEM)-based analysis procedures, structural optimisation strategy, physical prototyping, physical testing and design validation procedures. Following the visual and physical validation procedures carried out in the case study, the crane’s physical prototype was manufactured and the optimised design was approved for ongoing production. The study provides a unique CAD/CAE and experimentally driven total design pathway for similar products, which contributes to further research into the utilisation of engineering simulation technology for agricultural machinery design, analysis and related manufacturing subjects.