This paper introduces a new rotor design for the easy insertion and removal of rotor windings. The shape of the rotor is optimized based on a surrogate method in order to achieve low power loss under the maximum power output. The synchronous machine with the new rotor is evaluated in 2-D finite element software and validated by experiments. This rotor shows great potential for reducing the maintenance and repair costs of synchronous machines, making it particularly suited for low-cost mass production markets including gen-sets, steam turbines, wind power generators, and hybrid electric vehicles.