This paper proposes a robust design optimization methodology under design uncertainties of an aerospace vehicle propulsion system. The approach consists of 3D geometric design coupled with complex internal ballistics, hybrid optimization, worst-case deviation, and efficient statistical approach. The uncertainties are propagated through worst-case deviation using first-order orthogonal design matrices. The robustness assessment is measured using the framework of mean-variance and percentile difference approach. A parametric sensitivity analysis is carried out to analyze the effects of design variables variation on performance parameters. A hybrid simulated annealing and pattern search approach is used as an optimizer. The results show the objective function of optimizing the mean performance and minimizing the variation of performance parameters in terms of thrust ratio and total impulse could be achieved while adhering to the system constraints.