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This paper proposes a novel topology optimization method to optimize the material distribution of electrical machines using the genetic algorithm (GA). In the proposed method, a cluster of material and the cleaning procedure are taken into account in order to form a group of iron and a group of air. Moreover, the GA is iterated with the newly increased length of genes. The proposed method is applied to the topology optimization of the stator teeth in a brushless dc motor in order to reduce the torque ripple without decreasing the average torque. The proposed method makes it easier to manufacture the designed device.