Mechanical Design Synthesis (MDS) is an evolutionary step in design methodology. It combines several past steps such as Design by Analysis, Finite Element Analysis, Dynamic Mechanism Modeling, Thermal Analysis, Parametric Sensitivity, and Shape Optimization techniques under one software design environment. MDS can benefit every phase of the product development and delivery process and all members of the extended design team. A definition of MDS and a differentiation of MDS versus traditional methods are followed by a case study where MDS was used to trim 25% of the cost from a proposed design. The redesign project, which started with a nearly clean sheet of paper, was completed in 20% of the calendar time with a fourth as many people involved as in the first design attempt.