PurposeThis paper aims to investigate deterministic strategies for low-cost multi-objective design optimization of compact microwave structures, specifically, impedance matching transformers. The considered methods involve surrogate modeling techniques and variable-fidelity electromagnetic (EM) simulations. In contrary to majority of conventional approaches, they do not rely on population-based metaheuristics, which permit lowering the design cost and improve reliability.Design/methodology/approachThere are two algorithmic frameworks presented, both fully deterministic. The first algorithm involves creating a path covering the Pareto front and arranged as a sequence of patches relocated in the course of optimization. Response correction techniques are used to find the Pareto front representation at the high-fidelity EM simulation level. The second algorithm exploits Pareto front exploration where subsequent Pareto-optimal designs are obtained by moving along the front by means of solving appropriately defined local constrained optimization problems. Numerical case studies are provided demonstrating feasibility of solving real-world problems involving expensive EM-simulation models of impedance transformer structures.FindingsIt is possible, by means of combining surrogate modeling techniques and constrained local optimization, to identify the set of alternative designs representing Pareto-optimal solutions, in a realistic time frame corresponding to a few dozen of high-fidelity EM simulations of the respective structures. Multi-objective optimization for the considered class of structures can be realized using deterministic approaches without defaulting to evolutionary methods.Research limitations/implicationsThe present study can be considered a step toward further studies on expedited optimization of computationally expensive simulation models for miniaturized microwave components.Originality/valueThe proposed algorithmic solutions proved useful for expedited multi-objective design optimization of miniaturized microwave structures. The problem is extremely challenging when using conventional methods, in particular evolutionary algorithms. To the authors’ knowledge, this is one of the first attempts to investigate deterministic surrogate-assisted multi-objective optimization of compact components at the EM-simulation level.