Multi-objective reliability-based design optimization (MORBDO) is an efficient tool for generating reliable Pareto-optimal (PO) solutions. However, generating such PO solutions requires many function evaluations for reliability analysis, thereby increasing the computational cost. In this paper, a single-loop multi-objective reliability-based design optimization formulation is proposed that approximates reliability analysis using Karush-Kuhn Tucker (KKT) optimality conditions. Further, chaos control theory is used for updating the point that is estimated through KKT conditions for avoiding any convergence issues. In order to generate the reliable point in the feasible region, the proposed formulation also incorporates the shifting vector approach. The proposed MORBDO formulation is solved using differential evolution (DE) that uses a heuristic convergence parameter based on hypervolume indicator for performing different mutation operators. DE incorporating the proposed formulation is tested on two mathematical and one engineering examples. The results demonstrate the generation of a better set of reliable PO solutions using the proposed method over the double-loop variant of multi-objective DE. Moreover, the proposed method requires 6×–377× less functional evaluations than the double-loop-based DE.

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