In this study, a multi-objective shape optimization framework was established for photovoltaic-powered underwater vehicles (PUVs) to systematically investigate multidisciplinary coupled design methodologies. Specifically, a global sensitivity analysis was conducted to identify four critical design parameters with 24 h energy consumption and cabin volume serving as dual optimization objectives. An integrated automated optimization workflow was constructed by incorporating parametric modeling, computational fluid dynamics (CFD) simulations, and dynamic surrogate models. Additionally, a new phased hybrid adaptive lower confidence bound (PHA-LCB) infill criterion was designed under the consideration of error-driven mechanisms, improvement feedback loops, and iterative attenuation factors to develop high-precision dynamic surrogate models. Coupled with the NSGA-II multi-objective genetic algorithm, this framework generated Pareto-optimal front solutions possessing significant engineering value. Furthermore, an optimal design configuration was ultimately determined through multi-criteria decision analysis. Compared to the initial form, it generates an additional 1148.12 Wh of electrical energy within 24 h, with an 22.36% increase in sailing range and a 2.77% improvement in cabin volume capacity. The proposed closed-loop “modeling–simulation–optimization” framework realized multi-objective optimization of PUV shape parameters, providing methodological paradigms and technical foundations for the engineering design of next-generation autonomous underwater vehicles.

To address the limited endurance of unmanned underwater vehicles (UUVs) during long-duration missions, this study proposes a foldable and retractable wave energy converter (WEC) conformally integrated with the UUV hull. A two-degrees-of-freedom heave-coupled dynamic model of the float–UUV system is established, and parameter-matching relationships are derived using complex dynamic stiffness and impedance-matching theory. A bidirectionally coupled STAR-CCM+-AMESim co-simulation framework resolves the nonlinear viscous flow field, relative motion, and PTO dynamic response in closed loop. Under regular wave conditions defined based on a representative Bohai Sea state, the effects of the transmission ratio and spring stiffness on the coupled motion and equivalent resistive load power output are systematically investigated. Under the specified wave condition, average electrical power varies unimodally with both parameters, reaching 70.8 W at a transmission ratio of 15 and a spring stiffness of 4642 N/m; the corresponding peak power is 161.2 W. The system is more sensitive to increases than decreases in transmission ratio, suggesting a value slightly below the theoretical optimum for engineering design. The instantaneous power shows an asymmetric double-peak pattern, indicating a shift in dominance between direct float-driven generation and spring-mediated energy release. Agreement between theory and co-simulation provides numerical cross-validation and offers a theoretical basis and numerical methodology for designing and optimizing WECs on mobile UUV platforms.