The work aims to select a lightweight aluminum alloy pallet structure satisfying the requirements of pallet load-carrying performance based on the analysis of different pallet structures. 3D modeling of different types of pallets was carried out with SolidWorks software, the static analysis was carried out with Ansys Workbench, and the stress, deformation and safety factor of different types of pallets were compared. Then, the optimal aluminum alloy pallet was selected and its size was optimized. In scheme C, the pallet quality, and the stress, deformation and safety factor of the stringer were 19.68 kg, 247.39 MPa, 3.41 mm and 1.13, respectively, better than other types of pallets. After the thickness of top deck and the relevant sizes of the stringer were optimized, its mass was reduced by 22% and the safety factor of the stringer was increased by 20.4%. The aluminum alloy pallet in scheme C in which the thicknesses of the top deck and cushion are 1 mm and 1.5 mm, and other relevant sizes are 5, 5 and 30 mm respectively is the optimal structure when the load remains constant.