This paper describes the optimization methodology used in the design of a tubular slotted PM actuator for industrial applications. A time effective optimization procedure is obtained by considering simple analytical design equations in coherence with 2D finite element analysis as means to establish the various design variables. The original optimization problem is replaced by a surrogate, which is updated/improved iteratively by means of a space mapping based technique. Its application for solving coupled magnetic-thermal design problems for electric machines is a rather unexplored topic. The optimization is performed in a multi-physics environment, since both electromagnetic and thermal models are created and used in the optimization routi...