Purpose <p>This paper introduces the design, optimization, and performance evaluation of an electromagnetic vibration energy harvester, with the primary objective of enhancing its power output. In the literature, finite element analysis (FEA) software has been employed to model, simulate, and optimize the structural parameters, thereby providing a systematic methodology for the harvester’s design.</p> Methods <p>The paper introduces a novel electromagnetic vibration energy harvester, which employs a configuration featuring a pair of planar springs and opposing magnets enclosed by an iron core. The iron core encircles both the magnets and the coil, providing a quasi-closed magnetic path. This quasi-closed magnetic structure can considerably boost the coil’s magnetic flux linkage, thereby increasing the harvester’s output voltage. The planar springs have a single-degree-of-freedom motion, permitting minimal spacing between the moving mass and the coil. This proximity further augments the output voltage of the harvester.</p> Results <p>The experimental results demonstrated that the proposed energy harvester can generate a maximum power output of 8.92 mW with an acceleration of 0.1&#xa0;g at 49&#xa0;Hz resonant frequency, which is 6.46 times higher than that of the unoptimized energy harvester, achieving a normalized power density of 7.899 mWcm^-3g^-2.</p> Conclusion <p>These findings significantly enhance the performance of electromagnetic vibration energy harvesters and emphasize the importance of parameter optimization in maximizing power output. Furthermore, t the developed harvester holds considerable potential for applications in the field of machine condition monitoring.</p>