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The main aim of this work is to present the results of the shape design optimization process of an interior permanent-magnet synchronous motor. The shape design optimization process is accomplished based on the variations of the rotor structure using the Taguchi method. The time-stepping finite-element method is used for analysis of the motor. It is found that the optimal two-layer Machaon design has the lowest torque pulsation compared with the other structures. Finally, the optimized Machaon and preliminary one-layer interior permanent-magnet synchronous motors, which are amended from industrial three-phase induction motors, are manufactured. The results of numerical, analytical, and practical tests are in good agreement. [ABSTRACT FROM AUTHOR]