Hi Analyst,
The HyperSizer sizing method orders your 90,000 candidate designs in order of increasing unit weight. It then begins checking through all candidate designs until it reaches one with all positive margins of safety. If there are multiple designs with the same unit weight and more than one of them has all positive margins, then HyperSizer will select the design of those with the same unit weight that returns the highest margin of safety. Once it has found the design, it does not check heavier designs.
Let me know if this answers your question.
Phil