Plug-in hybrid electric vehicles (PHEVs) are considered as one of the most promising means to improve the near-term sustainability of the transportation and stationary energy sectors. This paper describes a methodology for the optimization of PHEVs component sizing using parallel chaos optimization algorithm (PCOA). In this approach, the objective function is defined so as to minimize the drivetrain cost. In addition, the driving performance requirements are considered as constraints. Finally, the optimization process is performed over three different all electric range (AER) and two types of batteries. The results from computer simulation show the effectiveness of the approach and the reduction in drivetrian cost while ensuring the vehicle performance. (C) 2010 Elsevier Ltd. All rights reserved.