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This paper presents the rotor and stator optimal design for a PM spherical stepper motor by experimental design method and the heat analysis is performed using 3-D FEM. Based on the torque characteristics analysis and full factorial design, three main control factors are selected and their effects on the torque characteristics are discussed in detail. As for the steady-state heat analysis, the relationships between the stator materials, thickness, and cooling modes with the temperature rise are simulated and the computation results are given. The results provide the theoretical guide for the further design, optimization and control research of the spherical stepper motor.