The work aims to take aluminum turnover boxes as research objects to conduct lightweight design of aluminum turnover boxes through finite element analysis and orthogonal experimental design to solve the problem of excess structural strength design. The stacking condition of aluminum turnover boxes was simulated and analyzed with the finite element analysis software Ansys Workbench. The findings were assessed with two failure criteria. The optimization scheme was designed based on orthogonal test. The mathematical model of the optimization scheme was built and calculated with Matlab. According to the simulation analysis, the first-order modal load factor was 6.98. The aluminum turnover box had a substantial safety margin based on the failure criterion. According to the range analysis, with self-weight of the box as the only indicator, it was determined that the thickness of the side column of the aluminum turnover box had the biggest effects on the self-weight of the box. Then, according to the mathematical model of the optimization scheme built and calculated with Matlab, the lightweight scheme decreased the self-weight by 9.88% at the mean time of meeting the working conditions. The aluminum turnover boxes of lightweight design meet the two criteria of strength failure and stable failure, as well as the actual operating conditions. It also demonstrates that the scheme of utilizing the orthogonal test approach and finite element analysis for lightweight design is feasible. It decreases the costs and increases the utilization rate of materials.