The optimisation of synchronous reluctance rotor topologies using the NSGA-II algorithm has been proven to be an effective method for calculating optimal solutions for various applications. However, increasing the number of design variables defines a vast design space, which necessitates constraints. These constraints reduce the number of possibilities and ensure feasibility; however, it could lead to Pareto-front fragmentation. The previous investigation of the presented machine design’s Pareto front identified such fragmentation. This paper investigates four different optimisation rounds of the same electric machine using the NSGA-II method to check for the cause of fragmentation. While Pareto front fragmentation is not widely covered in the literature for electric machines, this paper focuses on geometric feasibility-induced Pareto front fragmentation, which is solved by implementing a coupled constraint repair operator. The results show that by extending the design variable ranges and rewriting the feasibility constraints, not only can the fragmentation be repaired, but the average torque range of the Pareto front also improved from 779.76 mNm - 1823.83 mNm to 1046.48 mNm - 2149.129 mNm, while the torque ripple range reduced from 22.22% - 65.62% to 7.23% - 48.81%.