An optimization methodology for the design of a full-scale rotor blade with an active twist in order to enhance its ability to reduce vibrations and noise is presented. It is based on a 3D finite-element model, the planning of experiments, and the response surface technique to obtain high piezoelectric actuation forces and displacements with a minimum actuator weight and energy applied. To investigate an active twist of the helicopter rotor blade, a structural static analysis using a 3D finite-element model was carried out. Optimum results were obtained at two possible applications of macrofiber composite actuators. The torsion angle found from the finite-element simulation of helicopter rotor blades was successfully validated by its experimental values, which confirmed the modeling accuracy.