Dimensional synthesis is one of the most difficult issues in the field of parallel robots with actuation redundancy. To deal with the optimal design of a redundantly actuated parallel robot used for ankle rehabilitation, a methodology of dimensional synthesis based on multi-objective optimization is presented. First, the dimensional synthesis of the redundant parallel robot is formulated as a nonlinear constrained multi-objective optimization problem. Then four objective functions, separately reflecting occupied space, input/output transmission and torque performances, and multi-criteria constraints, such as dimension, interference and kinematics, are defined. In consideration of the passive exercise of plantar/dorsiflexion requiring large output moment, a torque index is proposed. To cope with the actuation redundancy of the parallel robot, a new output transmission index is defined as well. The multi-objective optimization problem is solved by using a modified Differential Evolution(DE) algorithm, which is characterized by new selection and mutation strategies. Meanwhile, a special penalty method is presented to tackle the multi-criteria constraints. Finally, numerical experiments for different optimization algorithms are implemented. The computation results show that the proposed indices of output transmission and torque, and constraint handling are effective for the redundant parallel robot; the modified DE algorithm is superior to the other tested algorithms, in terms of the ability of global search and the number of non-dominated solutions. The proposed methodology of multi-objective optimization can be also applied to the dimensional synthesis of other redundantly actuated parallel robots only with rotational movements. Dimensional synthesis is one of the most difficult issues in the field of parallel robots with actuation redundancy. To deal with the optimal design of a redundantly actuated parallel robot used for ankle rehabilitation, a methodology of dimensional synthesis based on multi-objective optimization is presented. First, the dimensional synthesis of the redundant parallel robot is formulated as a nonlinear constrained multi-objective optimization problem. Then four objective functions, separately reflecting occupied space, input / output transmission and torque performances, and multi-criteria constraints, such as dimension, interference and kinematics, are defined. In consideration of the passive exercise of plantar / dorsiflexion requiring large output moment, a torque index is proposed. To cope with the actuation redundancy of the parallel robot, a new output transmission index is defined as well. multi-objective optimization problem is solved by using a modified Differential Evolution ( DE, a special penalty method is presented to tackle the multi-criteria constraints. Finally, numerical experiments for different optimization algorithms are implemented. The computation results show that the proposed indices of output transmission and torque, and constraint handling are effective for the redundant parallel robot; the modified DE algorithm is superior to the other tested algorithms, in terms of the ability of global search and the number of non-dominated solutions. The proposed methodology of multi -objective optimization can be applied to the dimensional synthesis of other redundantly actuated parallel robots only with rotational movements.