In the development of an interior permanent magnet synchronous machine (IPMSM) for high-speed operation, the problem of mechanical stress of the rotor by centrifugal force becomes more essential as the speed and size of the machines increase. In this paper, the optimal design process combined with mechanical stress analysis was presented. In the analysis of mechanical stress, the node and element data obtained by the electromagnetic field analysis program are also used in the stress analysis. Therefore, the different pre-processing for the stress analysis program is no longer required. Therefore, the computing time of the new method is very short compared with the conventional approach, and when repeated analyzes of various models are required, this method is very useful. The validity of our methods was verified by comparing simulation results with conventional and experimental data.