Fault current limiter (FCL) is a kind of device with current-dependent impedance that has low impedance in normal state of power system, and high impedance during fault condition. Among all classes of FCLs, the saturated iron-core FCL (SICFCL) is practically the most favourable one nowadays. In this study, a numerical method for design and cost optimisation of SICFCLs is presented. It uses a set of constraints to ensure the desirable operation of the SICFCL based on its electrical and magnetic

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... haracteristics. For numerical calculations and optimisations, GAMS software has been used. Suitability of the method is approved by design, simulation and test of a 3500 VA prototype. Magnetic field distributions are simulated using COMSOL Multiphysics and performance of the designed SICFCL is evaluated in a power system hardware model. Simulation and experimental results show the satisfying agreement with predicted results by the proposed numerical method.