Today's increasingly competitive industrial environment demands shorter pro
duct development lead-times, lower costs, and higher quality products. Thes
e requirements produce more complex design problems that are characterized
by multiple design objectives as well as complex design objective and const
raint relations. The optimization of these computationally intensive design
problems leads to new technical challenges. This work applies a new global
optimization search scheme, the Adaptive Response Surface Method (ARSM), t
o the optimal design of a complex mechanical system -- the radiator stack P
EM fuel cell system, The design optimum manifests a significant increase in
system performance and decrease in cost. The proposed method can also be a
pplied to the solution of other complex design optimization problems.