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An optimal design methodology is developed in this paper for fuel cell hybrid electric vehicles (FCHEV) based on ordinal optimization (OO) and dynamic programming (DP); the optimal design aims to determine the appropriate sizes of the hydrogen tank, fuel cell, battery, and motor for the purpose of minimizing investment and operational cost given some specification of the car range, the road type and its gradeability. The DP simulates the operation of the vehicle for a set of specified components' sizes for given driving cycles and provides the total vehicle cost per year. The OO method offers an efficient approach for optimization by focusing on ranking and selecting a finite set of “good enough” alternatives through two models: a simple model and an accurate model. The OO program uses the specified sizes of the components that uniformly sample the search space and evaluates these designs using a simple but fast model.