Integrated Optimization of 3D Structural Topology and 2D Halbach Parameters for Maglev Planar Motor

•An integrated optimization of 3D structural topology and 2D Halbach parameters is proposed for maglev planar motor.•A streamlined optimization framework is constructed and proven to authentically guarantee smooth integrated optimization.•The integrated optimization method solves the coupling problem between electromagnet and stiffness of maglev planar motor.•Optimized structure improves thrust-mass ratio by 7.7%, power dissipation by 12.8%, and natural frequency by 16.6% compared to existing.•Mechatronic experiments show that the proposed integrated optimized motor can significantly improve the control bandwidth and reduce the current consumption.