The work aims to carry out lightweight design to the turnover aluminum box through topology optimization and size optimization methods to solve the problems of excessive structural strength design and unbalanced performance under multiple working conditions. Hyperworks was used to carry out finite element analysis on the stacking conditions, transportation impact conditions and lifting conditions of the turnover aluminum box, and the analysis results under each working condition were evaluated. A multi-condition topology optimization mathematical model based on compromise programming method was established, and the optimal load transfer path was obtained through optimization and solution by Optistruct. According to the topology optimization results, the secondary design and finite element analysis were carried out. Finally, the wall thickness of the new structure was divided into seven independent design variables, and the wall thickness was further optimized by the dimensional optimization method. The results of finite element analysis showed that the safety margin of the box structure designed based on experience was large, and the mechanical properties were not balanced under various working conditions. A new box structure was designed by compromise programming and topology optimization methods. Under the same wall thickness, the mass of the box was reduced by 10.15%, and the lateral stiffness was improved, so that the mechanical properties under each working condition were more balanced. According to the topology optimization scheme of the compromise programming model, the performance of the turnover aluminum box under various working conditions is collaboratively optimized, and the lightweight design of the box meets the use requirements under a variety of typical working conditions, which shows that the comprehensive use of the topology optimization and size optimization scheme of the compromise programming is feasible, and provides a theoretical basis for the lightweight design of metal packaging box.