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The rapid growth of the electric vehicle (EV) market demands highly efficient, compact, and reliable power electronics. Traditional manual design processes for On-Board Chargers (OBCs) are time-and costly consuming and prone to human error, hindering rapid market deployment. This paper presents a novel, integrated methodology for the automated design, simulation, and testing of OBCs to accelerate the development lifecycle. A method is proposed that combines multi-objective optimization algorithms with advanced component modelling to automatically synthesize optimal circuit topologies and component values based on user-defined constraints. After the automated design phase, the system seamlessly interfaces with high-fidelity simulation environments to validate transient and steady-state thermal and electrical performance. Finally, an automated Hardware-in-the-Loop (HIL) testing sequence is implemented to verify control algorithms and fault-handling capabilities before physical prototyping. Two case studies involving a 3 kW High Voltage OBC featuring a Vienna AC-DC PFC configuration and a 300W Interleaved Bridgeless boost PFC converter demonstrates that the methodology significantly reduces engineering design cycles while achieving a 98%, respectively 94% peak efficiency. This scalable framework provides a robust solution for power electronics engineers to meet the evolving demands of the automotive industry.