This work presents a methodology for optimizing multiple system level assembly characteristics of complex mechanical assemblies by placement of their components. It addresses any component shape (including nonconvex, hollow, sharp edges) connected together by functional constraints. This method presents the designer with multiple solutions to the engineering configuration design problem (ECDP) using a Pareto Genetic Algorithm working on a population of sets instead of a population of individual points and thus results in a more informed a posteriori decision on the tradeoff issues between the various objectives. This paper addresses the definition of the assembly components and their relationships (ECDP), the definition of the configuration design optimization method (CDOM), and shows the application of the CDOM to one academic and two engineering test cases.

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