A simultaneous engineering framework for designing optimal mechatronic syst
ems is presented. In the first part of this paper, a method, based on genet
ic algorithms, for optimizing the geometric configuration of three-axis mac
hine tools in the conceptual design stage is presented. The second part des
cribes a method, based on component mode synthesis, to derive a low-order c
ontrol model from a finite-element description of the mechanial and drive s
tructures of the mechatronic system. In the third part, motion controllers
are derived that are robust against configuration changes of the mechatroni
c system to be controlled.