The use of discrete variables in optimal design models offers the oppo
rtunity to deal rigorously with an expanded variety of design situatio
ns, as opposed to using only continuous variables. However, complexity
and solution difficulty increase dramatically and model formulation b
ecomes very important. A particular problem arising from the design of
a gear train employing four spur gear pairs is introduced and formula
ted in several different ways. An interesting aspect of the problem is
its exhibition of three different types of discreteness. The problem
could serve as a test for a variety of optimization or artificial inte
lligence techniques. The best known solution is included in this artic
le, while its derivation is given in a sequel article.