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This paper details the process involved in the numerical optimisation of a helicopter engine inlet electrothermal ice protection system. Although the process was developed using a production aircraft, it is demonstrated here using a generic intake and flight conditions, due to confidentiality of the actual design. The process includes adherence to the overall system design objectives (maximum power demand), including tolerances required to account for an industrial system (aircraft voltage variation, manufacturing tolerances). The numerical optimisation was performed using a combination of 2D and 3D methods to define the required heated area, power density, locations and settings for temperature control sensors. The use of 2D design tools allows a rapid iteration process to be performed, leading to the possibility of a higher level of optimisation within the allowable time-frame compared to the use of full 3D methods.