On of my most memorable courses in school was an evolutionary computation course. It dealt with algorithms like using genetic algorithms for search.

Interesting work.

One of the lectures I remember mentioned some work being done using genetic algorithms to design automotive fenders to absorb the greatest amount of energy.

I could imagine using GAs to design optimal screw heads. You'd need a set of restrictions, but I think physics models are well known and simple enough to do it.

Then there's the big question. What other common everyday objects do we overlook that could use a redesign using similar techniques?