This study dealt with the design process of the 78 kW permanent magnet synchronous generator for engines. After the calculation of the basic dimensions through a theoretical method in the process of initial model design, FEA (finite-element analysis) and a d,q-axis equivalent circuit were used to identify the generator characteristics depending on the number of poles. With the use of the space harmonic analysis method, the back-EMF (electromotive force) and THD were checked, and then the number of slots was determined. In addition, the most optimized generator dimensions were determined through a sizing optimization technique. Based on this, the optimum model with enhanced efficiency, material costs, and temperature characteristics was derived, and the availability of the design method was confirmed through a comparative analysis of the initial and optimum models.