Hi @statistic_nerd,
There are indeed several responses on this topic in the following discussions :
Custom Design: Default Number of Runs
how JMP design the number of runs for Default under DOE (custom design)
Plan optimal // facteurs catégoriels
After several experimentations and observations, here is what I found as guidelines for understanding the default number of runs proposed by JMP :
Depending on the minimum number of runs based on your assumed model, JMP will try to add minimum 4 runs to this minimum number of runs and ensure a balanced design. If this number of recommended runs is not balanced regarding the levels of some factors, JMP will add a number of runs to satisfy a good balance across all factors depending on their levels number. For example, if you have one categorical factor at 5 levels and another one at 3 levels, the minimum number of runs is 7 for a main effects model. Adding 4 runs won't help balance the design across all factors levels (11 is not a multiple of 5 and 3), so it will recommend a multiple of these 2 numbers, and the lowest number will be recommended, here 15.
For continuous factors only and main effects model, the default number of runs change by size 4 : from 2 to 3 factors, the default number of runs is 8, from 4 to 7 factors it's 12, from 8 to 11 it's 16, etc...
The number of runs is not affected by the choice of optimality criterion, as the calculated runs number is done prior computing the matrix. The recommended number of runs is influenced by the factors types, number of levels and the assumed model (as it impacts the minimum number of runs). The optimality criterion can however modify the treatments combination of factors levels in the added recommended runs (the experimental matrix) : I-optimality will favor new runs that can help minimize the average variance prediction over the design space for example. See Optimality Criteria for more info.
Hope this answer will help you,
Victor GUILLER
"It is not unusual for a well-designed experiment to analyze itself" (Box, Hunter and Hunter)