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• Integrating powertrain optimization and optimal control of a fuel cell mining truck. • Jointly considering energy efficiency and degradation cost of fuel cell and battery. • Multi-level fuel cell powertrain design/control optimization and implementation. • Robust and efficient global optimization method for complex optimization problem. • New methods to apply fuel cell to heavy duty vehicles at reduced lifecycle cost. Proton Exchange Membrane Fuel Cell (PEMFC) system, as a highly efficient, zero pump-to-wheel emission and quick refuelling energy conversion device, is particularly suited for heavy-duty transportation applications. An optimally designed hybrid powertrain with a battery energy storage system and optimal operation control can extend the operating life of the PEMFC system and reduce its lifecycle cost. This work focuses on the minimization of the lifecycle cost of a PEMFC hybrid electric propulsion system through the joint powertrain system design and control optimizations. The approach models and predicts the cost of hydrogen fuel determined by the energy efficiency of the powertrain, as well as the costs associated with the performance degradation and life-shortening of the PEMFC and the battery under a given vehicle operation profile. A nested, tri-level optimization problem is formulated for identifying the optimal powertrain component sizes and energy management parameters, and an advanced surrogate-based global optimization method is used to solve the complex optimization problem. The advantage of the new approach is revealed through the optimal design and control development of a representative mining truck operating under a real-world operation profile, reducing its mining tonnage specific cost by ten percent over its lifecycle. The new integrated design and control optimization method improved energy efficiency, reduced environmental pollutants, and lowered the lifecycle cost of fuel cell mining trucks, contributing to broader applications of the PEMFC technology. [ABSTRACT FROM AUTHOR]