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A novel coefficient modeling technique, using a coefficient estimation method, is introduced for a brushless DC (BLDC) motor with a skewed permanent magnet and overhang structure. To construct the novel coefficient, the 3-D FEM and a design of experiment (DOE) are utilized along with the moving least square method (MLSM). Also, to verify the accuracy of the novel coefficient modeling, the conventional coefficient modeling using LSM is constructed and compared. Then the novel coefficient is combined with an approximate model constructed by 2-D FEM for use with an optimal design algorithm. For the searching process to obtain an optimal point, the genetic algorithm (GA) is used. Three-dimensional FEM simulation is used to verify the accuracy of the novel coefficient for the optimal design.