The evolutionary structural optimization (ESO) method is established based on the linear elasticity theory and its changing structural topology leads to the problem of structural applicability. For this issue, we propose an improved evolutionary structural optimization (IESO) method, which reduces the yield limit of the material in ineffective elements to obtain the optimal material distribution. In particular, the proposed IESO method is investigated to be effective and accurate through the impact test of Taylor bar. Moreover, the Taylor bar optimized by the IESO method is difficult to manufacture by traditional machining and can be formed by additive manufacturing technology.