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Purpose The purpose of this paper is to perform an optimal design of a single-phase permanent magnet brushless DC motor (SPBLDCM) by using efficiency of the motor as an objective function. In the design procedure of the motor, a cuckoo search (CS) algorithm is used as an optimization tool.Design/methodology/approach For the purpose of this research work, a computer program for optimal design of electrical machines based on the CS optimization has been developed. Based on the design characteristics of SPBLDCM, some of the motor parameters are chosen to be constant and others variable. A comparative analysis of the initial motor model and the CS model based on the value of the objective function, as well as the values of the optimization parameters, is performed and presented.Findings Based on the comparative data analysis of both motor models, it can be concluded that the main objective of the optimization is realized, and it is achieved by an improvement of the efficiency of the motor.Practical implications The optimal design approach of SPBLDCM presented in this research work can be also implemented on other electrical machines and devices using the same or even other objective functions.Originality/value An optimization technique using CS as an optimization tool has been developed and applied in the design procedure of SPBLDCM. According to the results, it can be concluded that the CS algorithm is a suitable tool for design optimization of SPBLDCM and electromagnetic devices in general. The quality of the CS model has been proved through the data analysis of the initial and optimized solution. The quality of the CS solution has been also proved by comparative analysis of the two motor models using FEM as a performance analysis tool. [ABSTRACT FROM AUTHOR]