Compared　with　the　conventional　eddy　current,　pulsed　eddy　current　(PEC)　technology　has　the　characteristic　of　abundant　components　in　the　frequency　domain,　which　is　a　significant　technological　advancement.　Improvements　in　the　production　and　performance　of　PEC　sensors　are　necessary　for　nondestructive　testing.　Sensor　configuration　parameters　have　significant　influence　on　the　development　of　PEC　system.　In　this　study,　through　finite　element　simulation　and　experimental　investigation,　different　optimization　methods　for　PEC　sensors　are　compared　and　studied.　According　to　the　eddy　current　detection　principle,　a　two-dimensional　finite　element　simulation　model　was　established　to　study　the　influence　of　the　shape　and　size　parameters　of　cone-shaped　PEC　sensors.　Then　a　cone-shaped　PEC　sensor　was　optimized　by　the　orthogonal　methodology　and　the　response　surface　methodology,　respectively.　To　compare　the　effectiveness　of　the　optimization　methods,　two　optimized　sensors　were　fabricated.　It　was　demonstrated　that　the　combination　of　finite　element　method　and　response　surface　methodology　was　superior　for　improving　the　detection　performance　of　the　PEC　sensor　compared　with　the　orthogonal　methodology.　The　result　also　indicated　that　the　developed　cone-shaped　PEC　sensor　had　a　stronger　defect　detection　capability　than　cylindrical-shaped　PEC　sensors.　The　proposed　optimization　design　method　provides　a　feasible　reference　method　for　the　design　of　PEC　sensors　and　corresponding　parameters.