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As the core equipment for the electromagnetic emission system, the tubular permanent magnet linear synchronous motor (TPMLSM) is required to be of lighter weight and less power, taking the weight of the pulse power supply system into account. In this paper, a comprehensive optimization design method of TPMLSM is introduced, which is aimed to obtain a system-level optimal solution with strict dimensional and power restrictions. First, the calculation model of TPMLSM performance is established based on magneto-static field (2D-FEM) and response surface methodology (RSM), the precision is validated by transient field (2D-FEM). Then the optimal design procedure of TPMLSM is deduced, revealing clear advantages of the proposed model in design flexibility. Finally, the performances of all designs including both the motor and power system are calculated, listed, and optimized by selecting the optimal power level.