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The development method of solenoid actuators which are used as core components in automobile and aircraft industry is described. For optimal design of solenoid actuator general electromagnetic theory and empirical knowledge are simultaneously needed. First of all, the designer must perform the out-line design for the given item within a range of frame work by use of physical law and governing equations, and they carry out the optimal design through more detailed design process based on the empirical knowledge. In this paper, we present the optimal design method of low consumption type dc solenoid actuator using the simplified governing equations, electromagnetic theories, empirical design coefficients, and constrained optimization technique for solenoid actuator, and also show the design results and optimized design parameters for the dc 12 V, 0.5 W solenoid actuator.