In order to meet the requirements of emergency escape, the door opening and closing process of civil aircraft needs to be stable and should not be significantly shaken. The boarding door hinge arm is an important connection structure in the process of door opening and closing, which requires high rigidity. As the connection interface of multiple mechanisms, there are many types of load conditions applied on it. For the design of the boarding door hinge arm structure, a more comprehensive optimization design process is proposed, including design space definition, loads and boundary conditions, geometric reconstruction and stress analysis. Combining engineering experience, topology optimization, and thickness size optimization, the shape and size of the hinge arm can be determined in a small number of design iterations, which reduces the design period of the hinge arm and achieves lightweight design of hinge arm, while meeting the requirements for strength, stiffness, and functionality. For the key parameter settings in the design, suggestions are given to provide a reference for the design of similar structures.