In this paper, design and performance analysis of robust and inexpensive permanent magnet-assisted synchronous reluctance generators (PMa-SynRG) for tactical and commercial generator sets is studied. More specifically, the optimal design approach is investigated for minimizing volume and maximizing performance for the portable generator. In order to find optimized PMa-SynRG, stator winding configurations and rotor structures are analyzed using the lumped parameter model (LPM). After comparisons of stator windings and rotor structure by LPM, the selected stator winding and rotor structure are optimized using a differential evolution strategy (DES). Finally, output performances are verified by finite element analysis (FEA) and experimental tests. This design process is developed for the optimized design of PMa-SynRG to achieve minimum magnet and machine volume as well as maximum efficiency simultaneously.