In this paper particle swarm optimization (PSO) is used for a design optimization of a linear permanent magnet synchronous motor (LPMSM) considering ultra low thrust force ripples, low magnet consumption, improved efficiency and thrust. The influence of PM material is discussed, too and the modular poles are proposed to achieve the best characteristic. PM dimensions and material, air gap and motor width are chosen as design variables. Finally 2-D finite element analyses validate the optimization results