<p>The flux-barrier rotor topology, widely recognized as optimal for synchronous reluctance machines (SynRM), has well-established design parametrization guidelines. However, these conventional design rules face challenges when applied to small-diameter applications, particularly where manufacturing constraints limit design options. This study investigates the applicability of conventional flux-barrier design principles in a SynRM with a 25.24-mm rotor diameter and evaluates alternative rotor configurations. A comparative analysis was conducted between two conventionally parameterized flux-barrier designs, an innovative segmented rotor topology, and a theoretical three-barrier design. Finite element analysis revealed that the segmented rotor achieves superior performance with a saliency ratio of 2.07 and torque density of 2.2 × 10⁻⁵ N·m/mm³, comparable to larger machines reported in recent literature. At 5000 r/min and 50A, this configuration delivers 0.78 N·m torque with 45.75% efficiency and 0.63 power factor. Mechanical analysis confirmed structural integrity under high-speed operation, with maximum stress and deformation values of 6.2 × 10⁵ N/mm² and 5.47 × 10⁻⁵&#xa0;mm respectively. Experimental validation of a prototype largely corroborated simulation results though revealed higher torque ripple attributed to the modular stator construction necessitated by the small diameter. This study demonstrates that conventional flux-barrier design rules become less effective at small scales and presents a segmented rotor topology as a viable alternative, offering comparable performance while simplifying manufacturing processes.</p>