This study introduces a novel design for Magnetorheological dampers in automotive applications, with the objective of improving damping force in comparison to conventional MR dampers. The proposed MR damper, known as the Screw MR brake damper (SMRB damper), integrates a ball-screw mechanism with an MR brake to generate damping force. Through a comprehensive synthesis and analysis of relevant studies, the design and modeling of the SMRB damper are conducted using the Bingham plastic model and finite element method (FEM). Mathematical models are established to describe the damping force and friction torque of the proposed damper. To enhance damping force and minimize production costs, an PSO optimization method is employed to solve the optimization problem specific to the SMRB damper. The resulting optimal parameters will be utilized for fabrication and subsequent experimental validation, which is then compared with simulation results. The study emphasizes the potential of the newly designed SMRB damper as an effective solution for controlling vibrations in diverse applications, including vehicles, machinery, and buildings. This research contributes to the advancement of SMRB damper design and optimization, ultimately offering improved damping performance and expanded practical applications.